Weil-McLain Series 2 Manual
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Weil-McLain Series 2 Manual

Wall mount gas-fired water boilers
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See also: User's Information Manual
Boiler Manual
This manual must only be used by a qualifi ed heating installer/service technician. Read all instructions, including 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, death or substantial property damage.
Series 2
Wall Mount
Gas-Fired Water Boilers
70/110/155
• Installation
• Maintenance
• Startup
• Parts
Part number 550-142-190/1218
®

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Summary of Contents for Weil-McLain Series 2

  • Page 1 ® Series 2 Wall Mount Gas-Fired Water Boilers 70/110/155 Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualifi ed heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing.

  • Page 2: Table Of Contents

    ZONE VALVE zoning – primary/secondary ....51 Ratings — ECO Series 2 boilers ....127 CIRCULATOR zoning –...

  • Page 3: The Eco Series 2 Gas-Fired Water Boilers

    ® — Boiler Manual ERIES FIRED WATER BOILER The ECO Series 2 Gas-fired water boilers 1. Stainless steel firetube heat exchanger 17a. Electrical entrances (line voltage) The top left side knockouts are designated for line voltage wiring 2. Heat exchanger access cover/burner mounting plate only.
  • Page 4 ® — Boiler Manual ERIES FIRED WATER BOILER The ECO 70 Series 2 Gas-fi red water boilers (continued) Part number 550-142-190/1218...
  • Page 5 ® — Boiler Manual ERIES FIRED WATER BOILER The ECO 110 Series 2 Gas-fired water boilers (continued) Part number 550-142-190/1218...
  • Page 6 ® — Boiler Manual ERIES FIRED WATER BOILER The ECO 155 Series 2 Gas-fi red water boilers (continued) Part number 550-142-190/1218...

  • Page 7: Please Read Before Proceeding

    Weil-McLain boiler. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

  • Page 8: Boiler Location

    ® — Boiler Manual ERIES FIRED WATER BOILER Boiler location Installations must comply with: • Locate or protect the boiler so it cannot be damaged • Local, state, provincial, and national codes, laws, regulations by a moving vehicle. and ordinances. •...
  • Page 9 ® — Boiler Manual ERIES FIRED WATER BOILER Boiler location (continued) Provide clearances for service Provide clearances from combustible access — RECOMMENDED materials — REQUIRED 1. See Figure 1 for recommended service clearances. 1. See Figure 2 for REQUIRED minimum clearances. ALL installation must provide at least these minimums.

  • Page 10: Wall-Mounting The Boiler

    ® — Boiler Manual ERIES FIRED WATER BOILER Wall-mounting the boiler Remove boiler from crate Figure 3 Boiler shipping container . Use caution not to drop the boiler The boiler is heavy or cause bodily injury while lifting and handling. Verify that the boiler is securely attached to prevent possibility of boiler falling after installation.
  • Page 11 An optional accessory to allow the boiler to be placed on a level help guide the studs into the slots. The studs are attached to the back of floor is available from Weil-McLain. See kit instructions (available the boiler. on website) for details. See “BOILER ACCESSORIES” on page 115 4 Floor surface for part number information.

  • Page 12: Display Bracket Installation

    ® — Boiler Manual ERIES FIRED WATER BOILER Display bracket installation Determine display unit location Display installation on junction box 1. Boiler display unit can be mounted on either the right side of the 1. Ensure mounting location follows guidelines in boiler jacket or on the wall in close proximity to the boiler paragraph 3 of “Determine display unit location”.

  • Page 13: Boiler Hydrostatic Test

    ® — Boiler Manual ERIES FIRED WATER BOILER Boiler hydrostatic test DO NOT install a relief valve with a insert a ¾" NPT pipe plug in the relief valve tapping. TEMPORARILY pressure higher than 30 PSIG . This After the hydrostatic test, this plug must be removed and the relief is the maximum allowable relief valve valve must be installed.
  • Page 14 ® — Boiler Manual ERIES FIRED WATER BOILER Boiler hydrostatic test (continued) Figure 8 Install pipe fi ttings for relief valve and Figure 9 Install piping components required for hydrostatic test ( pressure/temperature gauge — see legend below) NOT mount relief valve until AFTER hydrostatic testing (see legend below) (155 only)

  • Page 15: Converting Boiler To Propane - Eco 70

    ® — Boiler Manual ERIES FIRED WATER BOILER Converting boiler to propane — ECO 70 Figure 10 Propane gas orifice identification Prepare boiler for propane — 70 (may be stamped 3.75) ECO 70 only (if required) Propane operation ALL ECO boilers must be converted for propane operation Converting an existing natural gas-fired boiler for propane...

  • Page 16: Converting Boiler To Propane - Eco 110

    ® — Boiler Manual ERIES FIRED WATER BOILER Converting boiler to propane — ECO 70 (continued) Figure 12 Installing the propane gas orifice (some details omitted for clarity) 7. See Figure 12. Insert the propane gas orifice (item 4) into the gas LEGEND for Figure 12 valve outlet as shown.

  • Page 17: Converting Boiler To Propane - Eco 155

    ECO 110 Gas valve and venturi 110. ECO 110 boiler Series 1 and ECO 110 boiler Series 2 boilers use different size orifices. You must confirm the series boiler you have and use the correct orifice size. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 18 ® — Boiler Manual ERIES FIRED WATER BOILER Converting boiler to propane — ECO 110 (continued) Figure 15 Installing the propane gas orifice (some details omitted for clarity) 7. See Figure 15. Carefully pull the gas valve down until it is free of the venturi.
  • Page 19 ® — Boiler Manual ERIES FIRED WATER BOILER Converting boiler to propane — ECO 155 Figure 16 Propane gas orifice identification Prepare boiler for propane — ECO 155 ECO 155 only (if required) Propane operation ALL ECO boilers must be converted for propane operation Converting an existing natural gas-fired boiler for propane...
  • Page 20 ® — Boiler Manual ERIES FIRED WATER BOILER Converting boiler to propane — ECO 155 (continued) Figure 17 Installing the propane gas orifice (some details omitted for clarity) Figure 18 Gas valve and venturi LEGEND for Figure 17 and Figure 18 Venturi (leave venturi attached to blower) (3) hex-head screws, 5mm hex (remove and retain) Gas valve...

  • Page 21: Gas Piping - Sizing Gas Lines

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

  • Page 22: Venting/Air Piping - General

    ® — Boiler Manual ERIES FIRED WATER BOILER Venting/air piping — general You must pipe combustion air to the Any improper operation of the common venting system should be boiler air intake corrected so the installation conforms with the National Fuel Gas Install air inlet piping for the ECO boiler Code, ANSI Z223.1/NFPA 54 - latest edition, and/or the Natural Gas as described in this manual.
  • Page 23 Maximum vent lengths apply for either 2" or 3" vent and air pipe. If using 2" pipe, provide 3"x 2" tappered reducers at boiler connections and at Weil-McLain vent/air cap or at concentric terminations. Boilers will derate as vent/air pipe length increases — see rating data on Figure 132, page 127 for derate amounts.
  • Page 24 ® Centrotherm Eco Systems — InnoFlue Weil-McLain stainless steel bird screens, 2" or 3" (purchase separately) — see Figure 119, page 115 for part numbers Note 1: Weil-McLain concentric vent kits are made from PVC ADAPTERS — AL29-4C piping — Install a PVC-to- pipe and fi ttings.

  • Page 25: Commonwealth Of Massachusetts Installations

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

  • Page 26: Vent Termination Requirements

    ® — Boiler Manual ERIES FIRED WATER BOILER Vent termination requirements Figure 24 The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance from adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.

  • Page 27: Boiler Room Air Openings

    ® — Boiler Manual ERIES FIRED WATER BOILER Boiler room air openings Figure 25 Combustion and ventilation air openings for Direct Vent installations, also follow the National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edition, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1 or applicable provisions of the local building codes.

  • Page 28: Direct Vent - Sidewall With Separate Pipes

    ® — Boiler Manual ERIES FIRED WATER BOILER DIRECT VENT — Sidewall with separate pipes Allowable vent/air pipe materials & Figure 26 INSTALLATION SEQUENCE — Separate pipes sidewall lengths Use only the vent materials and kits listed in Figure 23, page 24 . Provide pipe adapters if specifi...
  • Page 29 3. Use the provided paper template for correct location of hole centers. 4. Use of a sidewall termination plate is REQUIRED. a. Kits for several vent sizes are available from Weil-McLain. See “VENT/AIR PARTS AND KITS” on page 115. b. Plate may be field fabricated from corrosion resistant material of sufficient strength.

  • Page 30: Direct Vent - Sidewall Concentric

    ® — Boiler Manual ERIES FIRED WATER BOILER DIRECT VENT — Sidewall concentric Allowable vent/air pipe materials & Figure 29 INSTALLATION SEQUENCE — Concentric horizontal lengths 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 23, page 24 .
  • Page 31 ® — Boiler Manual ERIES FIRED WATER BOILER DIRECT VENT — Sidewall concentric (continued) Figure 30 See notices on previous page. Termination location — concentric termination — multiple boilers — clearance from vent of one to air intake of the next Install termination —...

  • Page 32: Direct Vent - Sidewall With W-M Vent/Air Plate

    See “Install Weil-McLain vent/air cap” on page 33 . All vent pipes and air inlets must Step 7 The Weil-McLain plate termination must be installed before piping terminate at the same height to avoid from the boiler to the termination.
  • Page 33 Use the template to mark the locations for the four mounting holes, flue pipe and air pipe. Level the template with a level. For the Weil-McLain plate, the template must be level to Figure 34 Hole preparation in wall — INSIDE VIEW ensure the flue and air pipe will be side-to-side, as shown...
  • Page 34 ® — Boiler Manual ERIES FIRED WATER BOILER DIRECT VENT — Vertical with separate pipes Allowable vent/air pipe materials & Figure 36 Separate pipes vertical termination lengths Use only the vent materials and kits listed in Figure 23, page 24 . Provide pipe adapters if specifi...

  • Page 35: Direct Vent - Vertical With Separate Pipes

    ® — Boiler Manual ERIES FIRED WATER BOILER DIRECT VENT — Vertical with separate pipes (continued) Figure 37 See notices on previous page. Terminations for multiple boilers Prepare roof penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
  • Page 36 ® — Boiler Manual ERIES FIRED WATER BOILER DIRECT VENT — Vertical concentric Allowable vent/air pipe materials & Figure 38 INSTALLATION SEQUENCE — Concentric vertical lengths 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 23, page 24 .

  • Page 37: Direct Vent - Vertical Concentric

    ® — Boiler Manual ERIES FIRED WATER BOILER DIRECT VENT — Vertical concentric (continued) Figure 39 See notices on previous page. Vertical termination — 3" PVC concentric — single or multiple boilers 2. Place roof penetrations to obtain minimum clearance of 12 inches between the edges of adjacent vent pipes of other boilers for U.
  • Page 38 ® — Boiler Manual erieS fired water boiler DIRECT VENT — Vertical vent /sidewall air Allowable vent/air pipe materials & lengths Figure 41 — Vertical vent/ INSTALLATION SEQUENCE sidewall air Use only the vent materials and kits listed in Figure 23, page 24. Provide pipe adapters if specified.

  • Page 39: Direct Vent - Vertical Vent /Sidewall Air

    ® — Boiler Manual ERIES FIRED WATER BOILER DIRECT VENT — Vertical vent /sidewall air (continued) Determine location for air inlet elbow Figure 42 Vent termination (through the roof) for 1. The air inlet of an ECO boiler is part of a direct vent connection. direct vent: vertical vent / sidewall air It is not classified as a forced air intake with regard to spacing from adjacent appliance terminations.

  • Page 40: Concentric Termination, Typical (Sidewall Or Vertical)

    ® — Boiler Manual ERIES FIRED WATER BOILER Concentric termination, typical (sidewall or vertical) LEGEND for Figure 44 Figure 44 PVC concentric termination assembly — DO NOT attach the rain cap until the termination has been 1 — Inner PVC pipe (vent) 4 —...

  • Page 41: Vent And Air Piping And Boiler Connections

    ® — Boiler Manual ERIES FIRED WATER BOILER Vent and air piping and boiler connections Follow termination instructions Figure 45 Boiler vent and air connections 1. Read and follow all instructions for the termination type used before proceeding with this page. Follow all instructions provided by vent pipe manufacturer.

  • Page 42: Install Water Piping

    See Replacement parts section at the end of this manual for support the boiler piping connections to prevent the Weil-McLain low water cut-off kit. them from turning could cause damage to boiler 4. Purchase low water cutoff and install in a tee in the supply components.

  • Page 43: Direct Connect System Piping

    ® — Boiler Manual ERIES FIRED WATER BOILER Direct Connect System Piping Primary/secondary piping to boiler Diaphragm- or bladder-type tank: Using primary/secondary piping will provide the most effi cient Refer to Figure 48 for suggested piping when using a diaphragm- and reliable operation of the boiler and the heating system.

  • Page 44: Closed-Type Expansion Tank

    ® — Boiler Manual ERIES FIRED WATER BOILER Direct Connect System Piping (continued) Closed-type expansion tank: Figure 50 Piping to closed-type expansion tank DO NOT use a closed-type tank if connecting to a water heater that is equipped with an automatic air vent.

  • Page 45: System Water Piping Methods

    ® — Boiler Manual ERIES FIRED WATER BOILER Direct Connect System Piping (continued) System water piping methods Install relief valve 1. Install relief valve in 1" x 1" x ¾" (for 70/110) or 1 ¼" x Head loss through boiler piping 1 ¼"...

  • Page 46: Zone Valve Zoning - Direct Connection

    2. The boiler and zone valves can also be operated by a Use isolation relays if connecting 3-wire zone valve end switches to the HEAT input. Weil-McLain WMZV zone controller. Note: This is a common legend for all piping diagrams. LEGEND for Figure 51 Not all items listed appear in every fi...

  • Page 47: Primary/Secondary System Piping

    ® — Boiler Manual ERIES FIRED WATER BOILER Primary/Secondary System Piping Expansion tank location Figure 52 Piping to diaphragm (or bladder) expansion tank Figure 52 and Figure 53 show typical installation of the system expansion tank. It is highly recommended that you locate the air separator and expansion tank as shown in the suggested piping drawings on pages 51 - 53 .

  • Page 48: Closed-Type Expansion Tank

    ® — Boiler Manual ERIES FIRED WATER BOILER Primary/Secondary System Piping (continued) Closed-type expansion tank Figure 53 Piping to closed-type expansion tank DO NOT use a closed-type tank if connecting to a water heater that is equipped with an automatic air vent. Figure 53 shows suggested piping when using a closed-type expansion tank, in which the air is directly in contact with tank water.

  • Page 49: System Water Piping Methods

    ® — Boiler Manual ERIES FIRED WATER BOILER Primary/Secondary System piping (continued) System water piping methods Figure 55 Estimated head loss of boiler loop piping and recommended circulators. Near boiler piping 1. Connect boiler to system only as shown in Figure 52, page 47 and Figure 53, page 48 .

  • Page 50: Install Relief Valve

    ® — Boiler Manual ERIES FIRED WATER BOILER Primary/Secondary System piping (continued) System circulators and zone circulators Install relief valve Install a system circulator or zone circulators as shown in the 1. Install relief valve in 1 " x 1 " x ¾" (for 70/110) or 1 ¼" x 1 ¼" piping diagrams in the Primary/Secondary System Piping x ¾"...

  • Page 51: Zone Valve Zoning - Primary/Secondary

    ® — Boiler Manual ERIES FIRED WATER BOILER Primary/Secondary System piping (continued) ZONE VALVE zoning – primary/ Figure 56 Zone valve zoning — primary/secondary secondary connection — a system circulator is required (Shown with optional DHW piping) See Figure 56 . 1.

  • Page 52: Circulator Zoning - Primary/Secondary

    60 , for instructions on wiring to circulators. 2. The boiler and circulators can also be operated by a Weil-McLain WMCR zone controller. LEGEND for Figure 57 and Figure 58 Note: This is a common legend for all piping diagrams.
  • Page 53 DHW page 60 , for instructions on wiring to circulators. applications may violate Section 303 of 2. The boiler and circulators can also be operated by a Weil-McLain the 2007 Energy Act. See page 127 for WMCR zone controller.

  • Page 54: Multiple Boiler Installations

    ® — Boiler Manual ERIES FIRED WATER BOILER Multiple boiler installations Figure 59 Side-to-side mounting of multiple ECO boilers — OR — Placing multiple boilers 1. Locate multiple boilers with spacings shown in Figure 59 . Calculate required cross section (for area in square inches): 2.
  • Page 55 (continued) Sequencing multiple ECO boilers Maximum connected load per manifold: 1. Use a multiple-boiler controller, such as the Weil-McLain BCP, 2-inch manifold — 450 MBH BMC or BSC, to sequence boilers. Locate temperature sensors as 3-inch manifold — 1400 MBH required in the controller manual.
  • Page 56 FIRED WATER BOILER Multiple boiler installations (continued) Figure 63 Piping schematic — typical piping for multiple ECO boilers, using Weil-McLain Easy-Fit manifolds Legend for Figure 63 1 Flow/check valve 11 Check valve or backfl ow preventer, as required by applicable codes...
  • Page 57 2. DHW tanks are zoned with circulators as shown. 2. Pipe from the near-boiler piping to the DHW tank’s 3. DHW circulators should be controlled with a Weil-McLain boiler connections as shown in Figure 56, page 51 . WMCR zone controller.

  • Page 58: Install Condensate Line

    (typically with a pH from 3.2 to 4.5). Install a neutralizing filter when draining into metal pipe and if required by local codes. See Replacement parts section at the end of this manual for the Weil-McLain kit. Part number 550-142-190/1218...

  • Page 59: Gas Piping

    ® — Boiler Manual ERIES FIRED WATER BOILER Gas piping ECO boilers are shipped ready to fi re natural gas when tightening gas Use two wrenches piping at boiler, using one wrench to ONLY. You must install the propane orifi ce if the prevent the boiler gas line connection boiler will be connected to propane.

  • Page 60: Field Wiring

    ® — Boiler Manual ERIES FIRED WATER BOILER Field wiring Wiring must be N.E.C. Class 1. If original wiring ELECTRICAL SHOCK HAZARD — For your safety, as supplied with boiler must be replaced, use turn off electrical power supply at service entrance only type 105 °C wire or equivalent.
  • Page 61 ® — Boiler Manual ERIES FIRED WATER BOILER Field wiring (continued) Low voltage: Figure 69 Back of display circuit board - 4-pin terminal Mount low voltage wire grommet to desired low voltage knockout. Thermostat, aquastat, limit devices, and outdoor temperature sensor wire pairs should be routed through the grommet.
  • Page 62 ® — Boiler Manual ERIES FIRED WATER BOILER Field wiring (continued) Line voltage wiring (120 VAC) Figure 71 line voltage input and output connections (120VAC) Make the following line-voltage connections, some of which depend on your system and how the ECO control will be programmed.
  • Page 63 ® — Boiler Manual ERIES FIRED WATER BOILER Field wiring (continued) Low voltage wiring (24 VAC) Figure 72 low voltage input and output connections Make the following low-voltage connections, some of which depend on your system and how the ECO control will be programmed.

  • Page 64: Wiring Diagram - Schematic

    ® — Boiler Manual ERIES FIRED WATER BOILER Wiring diagram — schematic Figure 73 Schematic wiring diagram (see Figure 74, page 65 for legend and notes) Part number 550-142-190/1218...

  • Page 65: Wiring Diagram - Ladder

    ® — Boiler Manual ERIES FIRED WATER BOILER Wiring diagram — ladder Figure 74 Ladder wiring diagram (see Figure 73, page 64 for schematic wiring diagram) Part number 550-142-190/1218...

  • Page 66: Express Setup - Using Default Settings

    ® — Boiler Manual ERIES FIRED WATER BOILER EXPRESS SETUP — using default settings 9. If the system qualifies for direct connect system piping — The MANDATORY CONTROL SETTINGS (guidelines on page 43), reference the following pages for following settings must be checked and adjusted piping and control suggestions: if necessary: BOILER MODEL and HIGH a.

  • Page 67: Eco Control Operation

    ® — Boiler Manual ERIES FIRED WATER BOILER ECO control operation Figure 76 Control sequence of operation — You must ensure Temperature settings that the ECO control is set for the proper water temperatures for the system. Excessive water Display Control action temperature can cause significant property status...
  • Page 68 ® — Boiler Manual ERIES FIRED WATER BOILER ECO control operation (continued) Figure 77 ECO control display screens and typical navigation Part number 550-142-190/1218...

  • Page 69: Essential Settings

    ® — Boiler Manual ERIES FIRED WATER BOILER ESSENTIAL settings . Failure to THE CONTROL SETTINGS LISTED BELOW MUST BE MADE BEFORE STARTING THE BOILER comply could result in incorrect operation of the boiler, causing possible severe personal injury, death or substantial property damage.

  • Page 70: Eco Control Settings Menus

    ® — Boiler Manual ERIES FIRED WATER BOILER ECO control settings menus Figure 78 ECO control menu access — accessing contractor menus BEFORE PROCEEDING, perform essential 5. The CONTRACTOR MENU screen will show: control settings as instructed on page 69. a.

  • Page 71: Boiler Settings Menu

    110EBM in the Boiler Model selection. This boiler manual WWSD is for the 110 (Series 2) model. For older version of the 110 (Series 1) model, please reference the correct boiler manual. 1. WWSD stands for “warm weather shutdown.” It means the boiler will not be allowed to fire if the...

  • Page 72: Heating Settings Menu

    ® — Boiler Manual ERIES FIRED WATER BOILER HEATING SETTINGS menu Figure 81 HEATING SETTINGS menu (see Figure 82 Typical outdoor reset curves Figure 84, page 74 for setting values and descriptions) HEATING SETTINGS 1. The heating settings menu is for setting control operation OD RESET MAX during space heating.
  • Page 73 ® — Boiler Manual ERIES FIRED WATER BOILER HEATING SETTINGS menu (continued) Figure 83 System Settings Recommended: System type Recommended temperatures SUPPLY MAX OD RESET MIN SUPPLY MIN OD RESET MAX Temp Temp Temp Temp Fan-coil Finned tube baseboard (Default settings) Cast iron baseboard Cast iron radiators Radiant –...

  • Page 74: Dhw Settings Menu

    ® — Boiler Manual ERIES FIRED WATER BOILER HEATING SETTINGS menu (continued) Figure 84 HEATING SETTINGS menu (see Figure 78, page 70 for access information) High Menu/Item Units Default Comment Value Value °F SUPPLY MAX Required supply temp. at system design max. load SUPPLY MIN °F Minimum supply temp.

  • Page 75: Circulator Exercising And Freeze Protection

    ® — Boiler Manual ERIES FIRED WATER BOILER DHW SETTINGS menu (continued) ON DIFF Setting MAX ON TIME to off will cause the control to 1. The temperature must drop this many degrees below never switch to space heating while DHW call for heat is present.

  • Page 76: Diagnostic Menu

    ® — Boiler Manual ERIES FIRED WATER BOILER DIAGNOSTIC menu Figure 87 DIAGNOSTICS menu navigation (see Figure 78, page 70 for access information) Menus Next screen Next screen Next screen Next screen Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data DIAGNOSTICS TEMPERATURES STATUS: ##########...
  • Page 77 ® — Boiler Manual ERIES FIRED WATER BOILER DIAGNOSTICS menu (continued) Figure 88 DIAGNOSTICS menu details (see Figure 87, page 76 for access information) Menu/Item Units High Default Comment Value Value TO RESET ALL HISTORY To reset all history and counters to zero: Enter the DIAGNOSTICS menu. Then press and hold AND COUNTERS TO ZERO: the left and right arrows located below the display.

  • Page 78: Date And Time Menu

    ® — Boiler Manual ERIES FIRED WATER BOILER DIAGNOSTICS menu (continued) Figure 89 DIAGNOSTICS menu details (continued) (see Figure 87, page 76 for access information) Menu/Item Units High Default Comment Value Value TO RESET ALL HISTORY To reset all history and counters to zero: Enter the DIAGNOSTICS menu. Then press and hold AND COUNTERS TO ZERO: the left and right arrows located below the display.

  • Page 79: Startup - Fill The System

    Startup — fill the system Clean system to remove sediment Antifreeze 1. Use only antifreeze listed by Weil-McLain as suitable for 1. You must thoroughly flush the system (without boiler use with ECO Gas Boilers. See Figure 119, page 115 for connected) to remove sediment.
  • Page 80 4. See separate instructions or Weil-McLain website for suggested . Freeze protection fluid may leak guidelines to determine how much inhibitor to use. before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

  • Page 81: Startup - Final Checks

    ® — Boiler Manual ERIES FIRED WATER BOILER Startup — fi nal checks Inspect/fi ll condensate system Check for gas leaks Inspect/check condensate lines and fi ttings Inspect the condensate drain line, condensate PVC fi ttings and Before starting the boiler, and during initial operation, condensate trap.
  • Page 82 ® — Boiler Manual ERIES FIRED WATER BOILER Startup — final checks (continued) ❏ Final checks before starting boiler Propane boilers — verify conversion ❏ Read the instructions to adjust and set up the control. 1. Verify boiler has been converted for propane. See page 15 ❏...
  • Page 83 ® — Boiler Manual ERIES FIRED WATER BOILER Startup — final checks (continued) Figure 92 Operating instructions (WARNING -Verify that the control is set for the correct boiler model before proceeding.) Part number 550-142-190/1218...
  • Page 84 Restore fi ring rate to AUTO. DO NOT adjust throttle on low fi re. result in severe personal injury, death or 7. Consult your local Weil-McLain representative if acceptable results substantial property damage. cannot be obtained for both high and low fi re.
  • Page 85 4. Clear the Lockout condition by selecting “Manual Reset” in on low fi re. the Diagnostic Menu. 7. Consult your local Weil-McLain representative if acceptable 5. Open the manual gas valve located on the gas line to resume results cannot be obtained for both high and low fi re.
  • Page 86 Restore fi ring rate to AUTO. DO NOT adjust throttle on low fi re. 5. Open the manual gas valve located on the gas line to 7. Consult your local Weil-McLain representative if acceptable results resume fuel supply to the boiler.

  • Page 87: Check-Out/Startup Verification

    , page 129. ❏ Followed Operating Instructions, Figure 92, page 83? ❏ Fill out the warranty registration card and send to Weil-McLain. ❏ Burner flame and combustion verified per page 82? ❏ Return instructions to envelope and give to owner or place ❏...

  • Page 88: Annual Startup And General Maintenance

    ® — Boiler Manual ERIES FIRED WATER BOILER Annual startup and general maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

  • Page 89: Annual Startup

    FIRED WATER BOILER Annual startup HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS It is recommended that you obtain a Weil-McLain Boiler Maintenance kit before attempting the REMOVING BURNER GASKET or first-year inspection, to ensure all parts that may COVER PLATE INSULATION be needed are available .
  • Page 90 ® — Boiler Manual ERIES FIRED WATER BOILER Annual startup (continued) Clean condensate trap The boiler should be inspected and 1. See Figure 98. started annually, at the beginning of 2. Slide bracket off of condensate trap then disconnect top the heating season, only by a qualified nut that secures the trap body to the boiler condensate service technician.
  • Page 91 ® — Boiler Manual ERIES FIRED WATER BOILER Annual startup (continued) Check air openings • Do not use automatic air vents in systems with closed-type tanks. The air will escape from the system instead of returning to the tank. 1. Verify that combustion and ventilation air openings to the boiler room and/or building are open and •...
  • Page 92 6. Inspect the flame at high and low fire. If flame is still not 3. Verify all wiring is in good condition and securely acceptable, check combustion values. If combustion is properly attached. adjusted, obtain a replacement burner from Weil-McLain. 4. Check ground continuity of wiring using continuity meter. Check flame signal 5.
  • Page 93 3. If the flue temperature is higher than this, shut B149.1. down the boiler, allow to cool, and follow the For elevations above 10,000 feet, please contact Weil-McLain procedure starting on page 105 to clean the heat Technical Support for details.
  • Page 94 ® — Boiler Manual ERIES FIRED WATER BOILER Annual startup (continued) Check boiler relief valve Reinstall jacket door after servicing 1. Inspect the relief valve and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufacturer’s warning label.

  • Page 95: Troubleshooting

    ® — Boiler Manual ERIES FIRED WATER BOILER Troubleshooting Before calling for troubleshooting assistance, fi ll in the “ ” ( page 130 ). ECO Gas Data Collection Sheet 1. See Figure 101 for tools and kits recommended for troubleshooting Record the boiler size and CP number (located on the ECO boilers.
  • Page 96 ® — Boiler Manual ERIES FIRED WATER BOILER Troubleshooting (continued) Check control fuses Figure 103 Control fuses ALWAYS check ECO control fuses before replacing ECO control or any major components (blower, etc.). If one Line Voltage of these fuses is blown, it can prevent ECO control or other components from operating.
  • Page 97 ® — Boiler Manual ERIES FIRED WATER BOILER Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a complete diagnosis. ECO control fault indications 1. T h e E C O c o n t r o l p r o v i d e d 2.
  • Page 98 ® — Boiler Manual ERIES FIRED WATER BOILER Troubleshooting (continued) Figure 105 Troubleshooting suggestions for ECO boilers — ECO control Error Condition Log The ECO control is able to record information about the boiler’s condition at the time of the three previous faults or errors. This information is available to view in Contractor Menus under “DIAGNOSTICS”...
  • Page 99 ® — Boiler Manual ERIES FIRED WATER BOILER Troubleshooting (continued) Figure 106 Troubleshooting suggestions for ECO boilers — Fault displays, diagnostics and corrective actions Condition Diagnostics Corrective Action(s) Display Control is not receiving Check wiring for short circuit or Correct wiring per wiring diagram including connection of transformer Nothing shown 24V power incorrect wiring.
  • Page 100 Inspect vent system for abnormal wear or damage. Reset using manual reset screen on display. Contact Weil-McLain Technical Support. Occurs if low water cutoff Automatic reset occurs if contacts Check for low water condition in system. Repair system as necessary refer LOW WTR contacts open.
  • Page 101 ® — Boiler Manual ERIES FIRED WATER BOILER Troubleshooting (continued) Figure 108 Troubleshooting suggestions for ECO boilers — Fault displays, diagnostics and corrective actions Condition Diagnostics Corrective Action(s) Display Boiler temperature sensor Reset using manual reset screen Verify that high limit setting is at least 10°F above the supply target HIGH TEMP reached High Temp Limit on display.
  • Page 102 ® — Boiler Manual ERIES FIRED WATER BOILER Troubleshooting (continued) Figure 109 Troubleshooting suggestions for ECO boilers — Fault displays, diagnostics and corrective actions Condition Diagnostics Corrective Action(s) Display IGNITION Boiler went through 5 Automatically resets after 1 hour Check condensate trap for blockage allowing condensate to accumulate FAULT ignition attempts and never or can be reset by performing...

  • Page 103: Maintenance

    ® — Boiler Manual ERIES FIRED WATER BOILER Maintenance Oiled bearing circulators DO NOT SERVICE THE BOILER 1. Check circulators in the system. Oil any circulators requiring WITHOUT A ECO MAINTENANCE oil, following circulator manufacturer’s instructions. Over- KIT AVAILABLE oiling will damage the circulator. The ECO maintenance kit includes components that may have to be replaced when accessing or disassembling parts of the boiler.
  • Page 104 SIDE, when required dish seal check 1. Isolate the boiler from the heating system. 2. Obtain Sentinel X400 cleaner from Weil-McLain. Follow instructions supplied with the cleaner to clean the boiler heat exchanger. Use ONLY the cleaning product available from Weil-McLain, Sentinel X400.

  • Page 105: Cleaning Heat Exchanger Flue Side, 70

    ® — Boiler Manual ERIES FIRED WATER BOILER Cleaning heat exchanger flue side, 70 Cleaning the ECO 70 heat exchanger Figure 112 Legend for Figure 113, page 104 FLUE SIDE or accessing the burner, if required A Boiler interior 6 Heat exchanger cover plate The boiler contains ceramic fiber materials.

  • Page 106: Cleaning Heat Exchanger Flue Side, 110

    ® — Boiler Manual ERIES FIRED WATER BOILER Cleaning heat exchanger flue side, 70 (continued) Figure 113 Accessing the burner or heat exchanger (see Legend on page 105) Part number 550-142-190/1218...

  • Page 107: Cleaning Heat Exchanger Flue Side, 155

    ® — Boiler Manual ERIES FIRED WATER BOILER Cleaning heat exchanger flue side, 70 (continued) Inspect and clean the burner 4. Apply a ring of silicone adhesive on the cover plate (to secure the refractory). 1. See Figure 113, page 106 part D. 5.
  • Page 108 ® — Boiler Manual ERIES FIRED WATER BOILER Cleaning heat exchanger flue side, 110 Cleaning the ECO 110 heat exchanger Figure 114 Legend for Figure 115, page 107 FLUE SIDE or accessing the burner, if required A Boiler interior 4 Venturi gas line clip The boiler contains ceramic fiber materials.
  • Page 109 ® — Boiler Manual ERIES FIRED WATER BOILER Cleaning heat exchanger flue side, 110 (continued) Figure 115 Accessing the burner or heat exchanger (see Legend on page 108) Part number 550-142-190/1218...
  • Page 110 ® — Boiler Manual ERIES FIRED WATER BOILER Cleaning heat exchanger flue side, 110 (continued) Inspect and clean the burner 4. Apply a ring of silicone adhesive on the cover plate (to secure the refractory). 1. See Figure 115, page 109 part D. 5.
  • Page 111 ® — Boiler Manual ERIES FIRED WATER BOILER Cleaning heat exchanger flue side, 155 Disconnect the two wire harnesses connected to the Cleaning the ECO 155 heat exchanger blower and the wire harness connected to the gas valve. FLUE SIDE or accessing the burner, 3.
  • Page 112 ® — Boiler Manual ERIES FIRED WATER BOILER Cleaning heat exchanger flue side, 155 (continued) DO NOT gouge or crack the refractory. The refractory Figure 116 Legend for Figure 117, page 113 is made of ceramic fiber materials. Read the ceramic fiber WARNING on page 89 before handling or disposing of ceramic fiber materials.
  • Page 113 ® — Boiler Manual ERIES FIRED WATER BOILER Cleaning heat exchanger flue side, 155 (continued) Figure 117 Accessing the burner or heat exchanger (see Legend on page 112) Do NOT attempt to remove the burner from the heat exchanger cover plate without first removing the heat exchanger cover plate from heat exchanger.

  • Page 114: Replacement Parts

    Failure to replace Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size and include damaged components and to use only the parts description and part number of replacement part.
  • Page 115 VENT/AIR PARTS AND KITS (POLYPROPYLENE PIPE) 2" & 3" vent screens, templates and mounting hardware available from Centrotherm Eco Systems ONLY Centrotherm INNOFLUE SIDEWALL concentric vent/air kit Weil-McLain sidewall vent/air cap termination kit for PVC vent and 383-500-397 ICWT352 air pipes 3"...
  • Page 116 Display board bracket Mounting for the display to side of cabinet 383-800-227 Condensate bracket 70/110 (not shown) Bracket and plastic rivets 383-700-238 Condensate bracket 155 (not shown) Bracket and plastic rivets 383-700-239 Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-190/1218...
  • Page 117 ® — Boiler Manual ERIES FIRED WATER BOILER Replacement parts (continued) Figure 121 Jacket assembly — ECO 70/110/155 (see Figure 120, page 116 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-190/1218...
  • Page 118 Burner, gasket, and hardware (includes item 250) 383-700-246 — 383-700-107 — Burner gasket 383-700-247 — Heat exchanger water temperature sensor (one sensor for either boiler inlet or outlet water 511-724-296 temperature) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-190/1218...
  • Page 119 ® — Boiler Manual ERIES FIRED WATER BOILER Replacement parts (continued) Figure 123 Heat exchanger assembly ECO 70/110 (see Figure 122, page 118 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-190/1218...
  • Page 120 ® — Boiler Manual ERIES FIRED WATER BOILER Replacement parts (continued) Figure 124 Heat exchanger parts ECO 155 (see Figure 125, page 121 for illustration) Item Name Part Number Heat exchanger 383-800-231 Heat exchanger, condensate dish, cover plate, burner, igniter, sight glass, refractory, water sensors, gaskets, silicone, and hardware 383-800-233 (includes items 100, 130, 140, 160, 170,180, 190, 200, 210, and 270)
  • Page 121 ® — Boiler Manual ERIES FIRED WATER BOILER Replacement parts (continued) Figure 125 Heat exchanger assembly ECO 155 (see Figure 124, page 120 for part numbers) Part number 550-142-190/1218...
  • Page 122 Propane orifice — boilers converted to propane ONLY — available only with propane conversion kit — see — Figure 118, page 114 for information Gas flex line Gas pipe and hardware 383-800-241 Gas pipe flange gasket Gasket, gas flex line to cabinet 590-300-027 Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-190/1218...
  • Page 123 ® — Boiler Manual ERIES FIRED WATER BOILER Replacement parts (continued) Figure 128 Combustion components for ECO 70/110 /155(see Figure 126, page 122 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-190/1218...
  • Page 124 Mixing Series 1 and Series 2 Control module and Display board will NOT work. ECO Series 2 Control module and Display may be used on a Series 1 boiler, if both Control and Display are changed out at the same time. For ECO 110 model, see Notice on page 71.
  • Page 125 ® — Boiler Manual ERIES FIRED WATER BOILER Replacement parts (continued) Figure 130 Controls and electrical assemblies — ECO 70/110/155 (see Figure 129, page 124 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-190/1218...

  • Page 126: Dimensions

    ® — Boiler Manual ERIES FIRED WATER BOILER Dimensions Dimensional data — ECO Series 2 70/110/155 DOO GLPHQVLRQV LQ LQFKHV Figure 131 FRONT RIGHT BOTTOM 1 Boiler supply tapping — 1" NPT -70/110, 1-1/4" NPT -155 5 Vent connection: 3" PVC 2 Boiler return tapping —...

  • Page 127: Ratings - Eco Series 2 Boilers

    — Boiler Manual ERIES FIRED WATER BOILER Ratings — ECO Series 2 boilers Figure 132 Ratings and engineering data — ECO 70/110/155 Series 2 boilers $+5, &HUWL¿HG 5DWLQJV % Input derate vs vent length Vent/ (Values shown are at MAX vent/air pipe...

  • Page 128: Ratings - Multiple Eco Series 2 Boilers

    ® — Boiler Manual ERIES FIRED WATER BOILER Ratings — Multiple ECO Series 2 boilers Figure 133 Ratings and engineering data — multiple ECO Series 2 boilers Boilers in Total Output / Boiler Net water Manifolded Notes system Input Heating H.P.

  • Page 129: Installation And Service Certificate

    Flame signal on control display at high fire __________________ Flame signal on control display at low fire __________________ Was orifice changed? _________ Was gas valve throttle adjusted? ______ Natural gas input rate measured HIGH________ CFH / LOW________ CFH ECO Series 2 Control Set-Up Data BOILER Settings HEAT Settings DHW Settings (if installed) °F...

  • Page 130: Eco Series 2 Gas Boiler Data Collection Sheet

    ® — Boiler Manual ERIES FIRED WATER BOILER ECO Series 2 Gas Boiler Data Collection Sheet Customer Info: Maintenance Info: Contact: Name: Contractor: Phone: Job name: Model: City, state: CP#: Distributor: Installed: Boiler/System Piping Details (Please Sketch) System Components: Near boiler pipe size:...
  • Page 131 ® — Boiler Manual ERIES FIRED WATER BOILER Notes Part number 550-142-190/1218...
  • Page 132 ® — Boiler Manual ERIES FIRED WATER BOILER Part number 550-142-190/1218...

This manual is also suitable for:

Eco 110Eco 155Eco 70

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