Weil-McLain Evergreen EVG 220 Manual
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Weil-McLain Evergreen EVG 220 Manual

Condensing gas boiler
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Boiler Manual
This manual must only be used by a qualified 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.
CONDENSING GAS BOILER
220/299/300/399
• Installation
• Maintenance
• Startup
• Parts
Part number 550-100-131/0120
®

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Summary of Contents for Weil-McLain Evergreen EVG 220

  • Page 1 ® CONDENSING GAS BOILER 220/299/300/399 Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualified 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.

  • Page 2: The Evergreen ® Gas-Fired Water Boilers

    — 220/299/300/399 Boiler Manual ® fired water boiler ® The Evergreen Gas-fired water boilers 1. Stainless steel firetube heat exchanger 2. Burner access cover/heat exchanger cover plate Evergreen control overview ® 3. Blower ® • The Evergreen control can operate a single boiler or coordi- ®...
  • Page 3 — 220/299/300/399 Boiler Manual ® fired water boiler ® The Evergreen Gas-fired water boiler (continued) Low voltage Line voltage – 3 – Part number 550-100-131/0120...

  • Page 4: Table Of Contents

    — 220/299/300/399 Boiler Manual ® fired water boiler Contents The Evergreen Gas-fired water boilers ® Please read before proceeding DO NOT SERVICE THE BOILER WITHOUT A Evergreen ® Boiler location MAINTENANCE KIT AVAILABLE Prepare boiler location Evergreen ® maintenance kit includes components that Wall-mounting the boiler may have to be replaced when accessing or disassembling Boiler hydrostatic test...

  • Page 5: Please Read Before Proceeding

    See the instructions contact with water, replace the boiler with a new Weil-McLain boiler. at right. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

  • Page 6: Boiler Location

    — 220/299/300/399 Boiler Manual ® fired water boiler Boiler location • Locate or protect the boiler so it cannot be damaged by Installations must comply with: a moving vehicle. • Ensure that the installation complies with all applicable • Local, state, provincial, and national codes, laws, regulations codes.
  • Page 7 — 220/299/300/399 Boiler Manual ® 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 installa- tion must provide at least these minimums.

  • Page 8: Prepare Boiler Location

    Wall-mounted boilers inch lag bolts or ¼” diameter for 3/16-inch toggle bolts. 1. Boilers can be wall mounted ONLY if using the optional wall- RECOMMENDED for drywall or plaster lathe. mount kit available from Weil-McLain. – 8 – Part number 550-100-131/0120...
  • Page 9 — 220/299/300/399 Boiler Manual ® fired water boiler Wall-mounting the boiler (continued) Wall-mounting requirements Figure 5 Place boiler on wall-mount bracket The wall-mounting kit is NOT supplied with the boiler, and must be purchased separately. Verify kit contents: a. Wall-mount bracket b.

  • Page 10: Boiler Hydrostatic Test

    — 220/299/300/399 Boiler Manual ® fired water boiler Wall-mounting the Boiler hydrostatic test boiler DO NOT install a relief valve with a pressure higher (continued) than 80 PSIG . This is the maximum allowable relief valve ® setting for the Evergreen boiler.
  • Page 11 — 220/299/300/399 Boiler Manual ® fired water boiler Boiler hydrostatic test (continued) Figure 6 Figure 7 Install piping fittings for relief valve and Install piping components required for pressure/temperature gauge –– DO NOT mount hydrostatic test (see legend below) relief valve until AFTER hydrostatic testing (see legend below) Piping to system Recommended but...

  • Page 12: Gas Conversions

    — 220/299/300/399 Boiler Manual ® fired water boiler Gas conversions Boiler hydrostatic test (continued) Prepare boiler for propane — 7. When water begins to exit from the supply outlet, close the boiler drain valve (item 12). Evergreen ® 220/299/300/399 (if required) 8.
  • Page 13 — 220/299/300/399 Boiler Manual ® fired water boiler Gas conversions (continued) Natural Gas to Liquefied Petroleum (Propane) conversion kits (continued) • Follow all instructions in proper order. • Do not tamper with venturi. DO NOT change or modify EVG 299/300 LP P/N 540-202-841 NG to Propane Gas Conversion Kit contents: venturi in any way.
  • Page 14 — 220/299/300/399 Boiler Manual ® fired water boiler Gas conversions (continued) Use two wrenches when tightening gas piping at LEGEND for Figures 11, 12, 13 and 14 boiler, using one wrench to prevent the boiler gas Air Silencer Gas valve line connection from turning.
  • Page 15 — 220/299/300/399 Boiler Manual ® fired water boiler Gas conversions (continued) Inspect the gas pipe fitting connections on the gas the offset regulating screw. DO NOT attempt to bottom out valve and new venturi (Item 3, Figure 14, page 14). the offset regulating screw as was done for the throttle adjust- Check the seal of the connections.
  • Page 16 — 220/299/300/399 Boiler Manual ® fired water boiler Gas conversions (continued) 20. Do NOT allow the boiler to modulate freely until the com- Table 2: Low-fire blower speeds—Minimum blower speed bustion analysis and adjustment is complete. Turn on and settings according to altitude settings. connect properly working, calibrated combustion analyzer to the boiler flue pipe.
  • Page 17 — 220/299/300/399 Boiler Manual ® fired water boiler Gas conversions (continued) Figure 18 Installer conversion label LP to Natural gas conversion 1. Follow the same instructions as LP conversion, except using the correct Natural gas conversion kit, See Figure 8, page 12 . 2.

  • Page 18: Gas Piping - Sizing Gas Lines

    — 220/299/300/399 Boiler Manual ® fired water boiler Gas piping — sizing gas lines Boiler gas connection is ¾” NPT. Size gas lines Figure 20 Pipe capacity for 0.60 specific gravity natural large enough to provide gas to all connected gas;...

  • Page 19: Venting/Air Piping - General

    — 220/299/300/399 Boiler Manual ® fired water boiler Venting/air piping — general You must pipe combustion air to the Evergreen boiler air intake ® Do not install the boiler into a common vent with any other appliance. This will cause flue gas spillage or Install air inlet piping for the Evergreen ®...
  • Page 20 Maximum vent lengths apply for either 3” or 4” vent and air pipe. If using 3” pipe, provide 4”x 3” tapered 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 123, page 129 for derate amounts.
  • Page 21 Dura-Vent — FasNSeal™ steel Metal-Fab, Inc. — CORR/GUARD Weil-McLain stainless steel bird screens, 3” or 4” (purchase separately) — see Figure 111, page 117 for part numbers Note 1: Weil-McLain concentric vent kits are made from PVC ADAPTERS — AL29-4C piping — Install a PVC-to-stainless pipe and fittings.

  • Page 22: Commonwealth Of Massachusetts Installations

    — 220/299/300/399 Boiler Manual ® 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 INSPECTION .

  • Page 23: Vent Termination Requirements

    — 220/299/300/399 Boiler Manual ® fired water boiler Vent termination requirements Figure 25 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 24: Boiler Room Air Openings

    — 220/299/300/399 Boiler Manual ® fired water boiler Boiler room air openings ® Figure 26 Evergreen Combustion and ventilation air openings for Direct Vent installations. Provisions for combustion and ventilation air to be in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes.

  • Page 25: Direct Vent - Sidewall With Separate Pipes

    — 220/299/300/399 Boiler Manual ® fired water boiler DIRECT VENT — Sidewall with separate pipes Allowable vent/air pipe materials & Figure 27 — Separate pipes sidewall INSTALLATION SEQUENCE lengths Use only the vent materials and kits listed in Figure 24, page 21. Provide pipe adapt- ers if specified.
  • Page 26 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 117. b. Plate may be field fabricated from corrosion resistant material of sufficient strength.

  • Page 27: Direct Vent - Sidewall With W-M Vent/Air Plate

    28. minate each vent/air connection as described in this manual. Step 8 The Weil-McLain plate termination must be installed before piping from the boiler to the termination. All vent pipes and air inlets must terminate at the same height to avoid possibility of severe...
  • Page 28 Hole preparation in wall — INSIDE VIEW (use template provided) For the Weil-McLain plate, the template must be level to ensure the flue and air pipe will be side-to-side, as shown in Figure 32. Failure to comply could result in severe personal injury, death or substantial property damage.

  • Page 29: Direct Vent - Sidewall Concentric

    — 220/299/300/399 Boiler Manual ® fired water boiler DIRECT VENT — Sidewall concentric Instructions below - are for the WM 3” and 4” PVC Concentric Kit. If using Simpson-Duravent or Centrotherm Figure 34 — Concentric INSTALLATION SEQUENCE Concentric kit, please refer to the manufacturer’s installation horizontal instructions.
  • Page 30 — 220/299/300/399 Boiler Manual ® fired water boiler DIRECT VENT — Sidewall concentric (continued) Figure 35 See notices on previous page. Termination location — concentric termination — multiple boilers — clearance from vent of one to air intake of Install termination — concentric pipes the next 1.

  • Page 31: Direct Vent - Vertical With Separate Pipes

    — 220/299/300/399 Boiler Manual ® fired water boiler DIRECT VENT — Vertical with separate pipes Allowable vent/air pipe materials & lengths Figure 37 Separate pipes vertical termination Use only the vent materials and kits listed in Figure 24, page 21. Provide pipe adapters if specified.
  • Page 32 — 220/299/300/399 Boiler Manual ® fired water boiler DIRECT VENT — Vertical with separate pipes (continued) Figure 38 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 33: Direct Vent - Vertical Concentric

    — 220/299/300/399 Boiler Manual ® fired water boiler DIRECT VENT — Vertical concentric Allowable vent/air pipe materials & lengths Figure 39 — Concentric vertical INSTALLATION SEQUENCE 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 24, page 21.
  • Page 34 — 220/299/300/399 Boiler Manual ® fired water boiler DIRECT VENT — Vertical concentric (continued) Figure 40 See notices on previous page. Vertical termination — concentric termination — single or multiple boilers 2. Place roof penetrations to obtain minimum of 12 inches between centers of adjacent vent pipe of another boiler for U.

  • Page 35: Concentric Termination, Typical (Sidewall Or Vertical)

    — 220/299/300/399 Boiler Manual ® fired water boiler Concentric termination, typical (sidewall or vertical) Figure 42 PVC concentric termination assembly — DO NOT LEGEND for Figure 42 — Inner PVC pipe (vent) attach the rain cap until the termination has been 2 —...

  • Page 36: Direct Vent - Vertical Vent / Sidewall Air

    — 220/299/300/399 Boiler Manual ® fired water boiler DIRECT VENT — Vertical vent / sidewall air Allowable vent/air pipe materials & lengths Figure 43 — Vertical vent/ INSTALLATION SEQUENCE sidewall air Use only the vent materials and kits listed in Figure 24, page 21.
  • Page 37 — 220/299/300/399 Boiler Manual ® fired water boiler DIRECT VENT — Vertical vent / sidewall air (continued) Determine location for air inlet elbow Figure 44 Vent termination (through the roof) for direct vent: vertical vent / sidewall air 1. The air inlet of an Evergreen boiler is part of a direct vent con- nection.

  • Page 38: Vent And Air Piping And Boiler Connections

    — 220/299/300/399 Boiler Manual ® fired water boiler Vent and air piping and boiler connections Follow termination instructions Figure 46 Boiler vent and air connections Read and follow all instructions for the termination type used before proceeding with this page. Follow all instructions provided by vent pipe manufacturer.

  • Page 39: Install Water Piping

    See Replacement parts section at the end of this manual for at boiler, using one of the wrenches to prevent the Weil-McLain low water cut-off kit. the boiler interior piping from turning. Failure to 4. Purchase low water cutoff and install in a tee in the supply support the boiler piping connections to prevent piping above boiler.
  • Page 40 For other piping methods, consult your local Weil-McLain Simplified pipe/circulator selection representative or see separate boiler piping guides. 1. Install the boiler and piping using the recommended piping Circulators layouts shown in this manual.
  • Page 41 6” above the floor This boiler is capable of a pressure up to 80 PSIG. Please see drain where any discharge will be clearly visible. miscellaneous Parts & Kits section for Weil-McLain alternate pressure components. The discharge line shall terminate plain, not 2.

  • Page 42: Expansion Tank

    — 220/299/300/399 Boiler Manual ® fired water boiler Expansion tank Expansion tank Figure 50 Piping to diaphragm (or bladder) type expansion tank Figure 50 and Figure 51 show typical installations of the system expansion tank. Always locate the air separator and expansion tank as shown in the suggested piping drawings, beginning on page 43.
  • Page 43 Controlling the circulators 1. The control can control up to four circulators (boiler circulator For more than 3-zones, use Weil-McLain WMZV zone valve and three others). Refer to Field wiring, beginning on page 52, for controller.
  • Page 44 1. The control can control up to four circulators (boiler circulator ing instructions, beginning on page 52, for details. and three others). Refer to Field wiring, beginning on page 52, for 3. For more than 3-zones, use Weil-McLain WMCR zone Circ instructions on wiring to circulators. controller.
  • Page 45 DHW demands and change TARGET MOD for details. SENSOR to System Supply. 3. For more than 3-zones, use Weil-McLain WMCR zone Circ 3. DHW Priority operation— Using Priority 1 for DHW controller. (default) will turn off lower priorities during DHW calls.
  • Page 46 DHW mode when system is intended for space heat- instructions, beginning on page 52, for details. ing may violate Section 303 of the 2007 Energy Act. See 3. For more than 3-zones, use Weil-McLain WMCR zone Circ page 129 for compliance information and exemptions. controller.
  • Page 47 52, for details. 1. The control can control up to four circulators (boiler circulator 3. For more than 3-zones, use Weil-McLain WMCR zone and three others). Refer to Field wiring, beginning on page 52, Circ controller. See EVG Advanced Manual for proper wiring.
  • Page 48 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 86 for details. Chilled medium, if used, is piped in parallel with heating boiler as shown in Figure 57.

  • Page 49: Install Condensate Line

    — 220/299/300/399 Boiler Manual ® fired water boiler Install condensate line Prepare condensate fittings Figure 58 Condensate trap assembly 1. Remove PVC fittings and gasket from the accessories bag. 2. Deburr and chamfer outside and inside of ½” PVC nipple to ensure even cement distribution when joining.
  • Page 50 (typically with a pH from 3.2 to 4.5). Install a neutralizing filter if required by local codes. See Re- placement parts section at the end of this manual for the Weil-McLain kit. Figure 61 Suggested condensate pump capacity, GPH...

  • Page 51: Gas Piping

    — 220/299/300/399 Boiler Manual ® fired water boiler Gas piping Figure 63 Connect gas supply piping Evergreen ® boilers are shipped ready to fire natural gas ONLY. You must install the propane venturi kit if the boiler will be connected to pro- pane.

  • Page 52: Field Wiring (See Wiring Diagram, Figure 65, Page 59)

    — 220/299/300/399 Boiler Manual ® fired water boiler Field wiring (see wiring diagram, Figure 65, page 59) Figure 64 Field wiring overview (see Figure 65, page 59 and Figure 66, page 60 for detailed schematic and ladder ELECTRICAL SHOCK HAZARD —...
  • Page 53 — 220/299/300/399 Boiler Manual ® fired water boiler Field wiring (see wiring diagram, Figure 65, page 59)(continued) A. 120 VAC Power Supply – REQUIRED Terminal Block T1 (control tray, right front) 1. Provide and install a properly-sized, fused disconnect or service switch as required by applicable codes.
  • Page 54 — 220/299/300/399 Boiler Manual ® fired water boiler Field wiring (see wiring diagram, Figure 65, page 59)(continued) C. 120 VAC to Boiler Circulator – REQUIRED Terminal Strip P8 on Pump/Comm Board (control tray, left side) 1. Provides 120VAC to the boiler circulator at Pump/Comm Board P8 Terminals. 2.
  • Page 55 — 220/299/300/399 Boiler Manual ® fired water boiler Field wiring (see wiring diagram, Figure 65, page 59)(continued) E. System supply and return temperature sensors – REQUIRED Terminal Block P14 (EVG control module, left side) 1. Two strap-on temperature sensors are shipped with the boiler. Attach one to the system supply piping and the other to the system return piping.
  • Page 56 1. Install a low water cut-off when required. 2. Wiring Weil-McLain LWCO Kit: a. When possible, use the Weil-McLain Low water cut-off kit listed in the back of this manual. It includes a probe-type low water cut-off and pro- vides a simple harness connection for the wiring.
  • Page 57 — 220/299/300/399 Boiler Manual ® fired water boiler Field wiring (see wiring diagram, Figure 65, page 59)(continued) K. Proof of closure (flow switch and/or CAD) – – see ADVANCED Manual OPTIONAL Jumper on Terminal Strip P7 (EVG control, bottom left of center) 1.
  • Page 58 — 220/299/300/399 Boiler Manual ® fired water boiler Field wiring (see wiring diagram, Figure 65, page 59)(continued) M. 0–10 VDC Remote MODULATION input – OPTIONAL Terminal Block P15 #5 & #6 (EVG control module, left side) 1. See illustration at right and Figure 65, page 59 for details. 2.

  • Page 59: Wiring Diagram - Schematic

    — 220/299/300/399 Boiler Manual ® fired water boiler Wiring diagram — schematic ® Figure 65 Evergreen schematic wiring diagram (see Figure 66, page 60 for legend and notes) – 59 – Part number 550-100-131/0120...

  • Page 60: Wiring Diagram - Ladder

    — 220/299/300/399 Boiler Manual ® fired water boiler Wiring diagram — ladder Figure 66 Evergreen ladder wiring diagram (see Figure 65, page 59 for schematic wiring diagram) – 60 – Part number 550-100-131/0120...

  • Page 61: Zoning With The Evg Control

    — 220/299/300/399 Boiler Manual ® fired water boiler Zoning with the EVG Control A. Zoning with CIRCULATORS, suggested applications Three space heating zones (no DHW) 1. Review wiring information on page 53 (120VAC out- puts) and page 54 (24VAC inputs). 2.
  • Page 62 — 220/299/300/399 Boiler Manual ® fired water boiler Zoning with the EVG Control (continued) B. Zoning with ZONE VALVES, suggested applications Two space heating zones (no DHW) 1. Review wiring information on page 53 (120VAC outputs) and page 54 (24VAC inputs). 2.

  • Page 63: Evergreen Control Operation

    — 220/299/300/399 Boiler Manual ® fired water boiler Evergreen Control operation Figure 67 Control sequence of operation Evergreen control setup 1. Set control parameters using the WIZARD option provided on initial start-up or manually enter parameters using control menus Display Control action (see Figure 74, page 75 and following pages for information.) status...
  • Page 64 — 220/299/300/399 Boiler Manual ® fired water boiler Evergreen Control operation (continued) EVG control Priorities & Input/Outputs Setting Up the Boiler • For heating installations with multiple systems, the EVG control • DETERMINE input/output needs – uses PRIORITIES to determine the order of operation of the •...
  • Page 65 — 220/299/300/399 Boiler Manual ® fired water boiler Evergreen Control operation (continued) Outdoor reset operation Figure 68 Outdoor reset operation 1. Set desired temperatures for space heating zones. 2. For an explanation of the target temperatures and associated outdoor temperatures, see Figure 68. 3.
  • Page 66 — 220/299/300/399 Boiler Manual ® fired water boiler Evergreen Control operation (continued) Figure 70 Evergreen single boiler essential settings (REQUIRED on initial start-up) — see page 74 for explanation – 66 – Part number 550-100-131/0120...
  • Page 67 — 220/299/300/399 Boiler Manual ® fired water boiler Evergreen Control operation (continued) Figure 71 Evergreen control display screens and typical navigation – 67 – Part number 550-100-131/0120...

  • Page 68: Express Setup - Example A

    — 220/299/300/399 Boiler Manual ® fired water boiler EXPRESS SETUP — e xample Multi-zone SPACE HEATING (Circulators with circulator relays) | DHW (Direct-piped) — EVG C vAlue must be set or verified ontrol settings Boiler Model, Altitude and Fuel Type are critical d —...
  • Page 69 — 220/299/300/399 Boiler Manual ® fired water boiler EXPRESS SETUP — e xample (continued) Multi-zone SPACE HEATING (Circulators with circulator relays) | DHW (Direct-piped) 14 Unions as needed Evergreen boiler. for service. Indirect water heater, if 15 Return tempera- used (domestic water ture sensor.

  • Page 70: Express Setup - Example B

    — 220/299/300/399 Boiler Manual ® fired water boiler EXPRESS SETUP — e xample 2- or 3-Zone SPACE HEATING (Circulators without circulator relays) | DHW (Direct-piped) — EVG C vAlue must be set or verified ontrol settings Boiler Model, Altitude and Fuel Type are critical d —...
  • Page 71 — 220/299/300/399 Boiler Manual ® fired water boiler EXPRESS SETUP — e xample (continued) 2- or 3-Zone SPACE HEATING (Circulators without circulator relays) | DHW (Direct-piped) 14 Unions as needed Evergreen boiler. for service. Indirect water heater, if 15 Return tempera- used (domestic water piping not shown) —...

  • Page 72: Express Setup - Example C

    — 220/299/300/399 Boiler Manual ® fired water boiler EXPRESS SETUP — e xample Multi-zone SPACE HEATING (Zone valves + WMZV controller) | DHW (Direct-piped) — EVG C vAlue must be set or verified ontrol settings Boiler Model, Altitude and Fuel Type are critical d —...
  • Page 73 — 220/299/300/399 Boiler Manual ® fired water boiler EXPRESS SETUP — e xample (continued) Multi-zone SPACE HEATING (Zone valves + WMZV controller) | DHW (Direct-piped) 13 Zone valves. Evergreen boiler. 14 Unions as needed Indirect water heater, if for service. used (domestic water piping not shown) —...

  • Page 74: Available Control Settings And System Presets

    — 220/299/300/399 Boiler Manual ® fired water boiler Available control settings and system presets Figure 72 Evergreen control settings available in BASIC MODE (see Advanced Manual for ADVANCED MODE settings) Available settings from CONTRACTOR MENU Boiler Settings Menu Priority 2 menu Assign Inputs menu Input 1: TT1 •...

  • Page 75: Contractor Menus

    — 220/299/300/399 Boiler Manual ® fired water boiler CONTRACTOR menus Boiler Model, Altitude and Fuel Type are criti- 1. Access contractor menus by pressing and holding the UP and cal settings. DOWN arrow keys at the same time for 7 seconds. Failure to set correctly could result in severe personal injury, death or substantial property 2.

  • Page 76: Boiler Settings Menu, Basic Mode

    — 220/299/300/399 Boiler Manual ® fired water boiler BOILER SETTINGS menu, BASIC mode Boiler Model, Altitude and Fuel Type are criti- 1. Access contractor menus by pressing and holding the UP and cal settings. DOWN arrow keys at the same time for 7 seconds. Failure to set correctly could result in severe personal injury, death or substantial property 2.

  • Page 77: Priority 1, 2, 3 Menus, Basic Mode

    — 220/299/300/399 Boiler Manual ® fired water boiler PRIORITY 1, 2, 3 menus, BASIC mode Boiler Model, Altitude and Fuel Type are criti- 1. Access contractor menus by pressing and holding the UP and cal settings. DOWN arrow keys at the same time for 7 seconds. Failure to set correctly could result in severe personal injury, death or substantial property 2.

  • Page 78: Assign Inputs Menu, Basic Mode

    — 220/299/300/399 Boiler Manual ® fired water boiler ASSIGN INPUTS menu, BASIC mode Boiler Model, Altitude and Fuel Type are criti- 1. Access contractor menus by pressing and holding the UP and DOWN arrow keys at the same time for 7 seconds. cal settings.
  • Page 79 — 220/299/300/399 Boiler Manual ® fired water boiler ASSIGN INPUTS menu, BASIC mode (continued) Figure 78 AUX PUMP/OUTPUT operation (accessed in ASSIGN INPUTS menu – see Figure 77, page 78) Option Activation conditions Suggested uses • Hot loop for seasonal boilers that are manually ALWAYS ON •...

  • Page 80: Diagnostic Menu

    — 220/299/300/399 Boiler Manual ® fired water boiler DIAGNOSTIC menu Figure 80 DIAGNOSTICS menu navigation (see Figure 71, page 67 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 81 — 220/299/300/399 Boiler Manual ® fired water boiler DIAGNOSTICS menu (continued) Figure 81 DIAGNOSTICS menu navigation, continued (see Figure 71, page 67 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 (cont.) NETWORK INPUTS Shows input status of all network boiler inputs.
  • Page 82 — 220/299/300/399 Boiler Manual ® fired water boiler DIAGNOSTICS menu (continued) Figure 82 DIAGNOSTICS menu details (see Figure 71, page 67 for access information) Menu/Item Comment Temperatures Status Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfied, post purge, Warm Weather Shut down, Trouble Boiler Out1 Temperature of t...
  • Page 83 — 220/299/300/399 Boiler Manual ® fired water boiler DIAGNOSTICS menu (continued) Figure 83 DIAGNOSTICS menu details (continued) (see Figure 71, page 67 for access information) Menu/Item Comment Run Times Burner Time Displays cumulative time the burner has been active (can be increased by user) Rotate Time Records the days of operation passed from the last time the Master boiler rotated the firing sequence.
  • Page 84 — 220/299/300/399 Boiler Manual ® fired water boiler DIAGNOSTICS menu (continued) Figure 84 DIAGNOSTICS menu details (continued) (see Figure 71, page 67 for access information) Menu/Item Comment Fault Type Displays the type of fault that occurred Time Displays time that lockout occurred Date Displays date that lockout occurred Status...

  • Page 85: Maintenance, Date And Time Menus

    — 220/299/300/399 Boiler Manual ® fired water boiler MAINTENANCE, DATE AND TIME menus Figure 85 MAINTENANCE, DATE AND TIME menus — navigation (see Figure 71, page 67 for access information) Comment Maintenance Info Name Contractor name to appear in maintenance reminders and during lockouts Phone Contractor phone number Model...

  • Page 86: Startup - Fill The System

    Antifreeze Measure the INLET gas pressure to the boiler Manometer (Inclined or digital) 1. Use only antifreeze listed by Weil-McLain as suitable for use Combustion testing and boiler adjustments Evergreen Combustion analyzer ® with Gas Boilers. See Figure 111, page 117 for (Digital preferred) information.
  • Page 87 4. See separate instructions or Weil-McLain website for suggested guide- to drop, reducing the freeze protection level. lines to determine how much inhibitor to use.

  • Page 88: Startup - Final Checks

    — 220/299/300/399 Boiler Manual ® fired water boiler Startup — final checks Fill condensate trap with water Check for gas leaks 1. Loosen the hose clamp securing the right end of the condensate trap to the PVC reducing elbow (see page 49 for details). Before starting the boiler, and during initial operation, 2.
  • Page 89 — 220/299/300/399 Boiler Manual ® fired water boiler Startup — final checks (continued) Figure 87 Operating instructions (WARNING — Verify that the Control is set for the correct boiler model before proceeding.) – 89 – Part number 550-100-131/0120...
  • Page 90 Check around the boiler and inside the boiler jacket for gas odor following the procedure of page 51 of this manual. contact your local Weil-McLain representative. Throttle screw adjustment must be done only If you discover evidence of any gas leak, shut down by a qualified technician, using calibrated test the boiler at once.
  • Page 91 3. In the event that the CO2 and CO cannot be ob- tained, please contact your Weil-McLain representative. 4. Should you require any assistance during the set up procedure contact your Weil-McLain representative if the problem cannot High Fire be addressed with the information provided in this manual.

  • Page 92: Check-Out/Startup Verification

    Replace any damaged gasket. 1. Operate the boiler on HIGH fire. d. Contact your Weil-McLain representative if the problem 2. Using an inspection mirror, move the mirror around all heat cannot be addressed with the information provided in exchanger joints and vent pipe connections at the top of the this manual.

  • Page 93: Annual Startup And General Maintenance

    — 220/299/300/399 Boiler Manual ® 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 94: Annual Startup

    The boiler should be inspected and started annually, at the beginning of the heating season, It is recommended that you obtain only by a qualified service technician. In addition, Evergreen a Weil-McLain ® Boiler the maintenance and care of the boiler designated Maintenance kit before attempting...

  • Page 95: Address Reported Problems

    — 220/299/300/399 Boiler Manual ® fired water boiler Annual startup (continued) Address reported problems DO NOT SERVICE THE BOILER Inspect any problems reported by owner and correct before Evergreen ® WITHOUT AN proceeding. INSPECTION KIT AVAILABLE Inspect boiler area 1. Verify that boiler area is free of any combustible materials, Before each annual inspection, obtain an EVG Inspection gasoline and other flammable vapors and liquids.

  • Page 96: Check All Piping For Leaks

    — 220/299/300/399 Boiler Manual ® fired water boiler Annual startup (continued) Check all piping for leaks • Make sure a closed-type tank is fitted with a tank fit- ting, such as the B & G Tank-Trol or Taco Taco-Trol. Eliminate all system or boiler leaks. Continual fresh This fitting reduces gravity circulation of air-saturated make-up water will reduce boiler life.

  • Page 97: Remove And Inspect Ignition Electrode Assembly And Wiring

    — 220/299/300/399 Boiler Manual ® fired water boiler Annual startup (continued) 3. Remove the air baffle (item 2) and screws (item 4) from the c. If the flame sense rod is bent or cannot be cleaned satis- factorily or if the ceramic is cracked or damaged, replace jacket top as shown.

  • Page 98: Replace All Components

    — 220/299/300/399 Boiler Manual ® fired water boiler Annual startup (continued) Figure 93 Accessing burner, ignition electrode, flame LEGE Figure 93 PARTS A and B ND — sense rod and inspection glass assembly (EVG 220 shown) Boiler interior assembled view (Model EVG 220 shown; component locations vary with other models) Boiler interior exploded view, showing heat exchanger cover plate (item 6) blower, burner assembly, burner access...

  • Page 99: Check All Boiler Wiring

    Figure 89, page 91. If manual. combustion can not be properly adjusted, obtain a replace- ment burner from Weil-McLain. 2. Verify cold fill pressure is correct and that operating pressure does not go too high. Adjust water pressure and expansion 7.

  • Page 100: Check Blower Speeds

    — 220/299/300/399 Boiler Manual ® fired water boiler Annual startup (continued) Check blower speeds Figure 96 Firing rates and corresponding blower speeds (low fire, ignition, and high fire) — for altitudes up to 5,500 feet and high altitude (above 5,500 feet). 1.

  • Page 101: Manual Test Mode For Single And Multiple Boilers

    — 220/299/300/399 Boiler Manual ® fired water boiler Annual startup (continued) Manual Test Mode for Single and Check boiler relief valve Multiple Boilers 1. Inspect the relief valve and lift the lever to verify Single Boiler flow as in the following warnings, excerpted from 1.

  • Page 102: Troubleshooting

    — 220/299/300/399 Boiler Manual ® fired water boiler Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING VERIFY PROPER OPERATION AFTER SERVICING BEFORE TROUBLESHOOTING — BEFORE TROUBLESHOOTING — Before calling for troubleshooting assistance, fill in the Evergreen Gas Data Collection Sheet “ ® ”...
  • Page 103 — 220/299/300/399 Boiler Manual ® fired water boiler Troubleshooting (continued) Check Control fuses 5. If necessary, replace one or all of the fuses: ALWAYS check control fuses before replacing a. Item 1 - Boiler Circ fuse is a 3-amp fast-blow (Littelfuse control or any major components (blower, etc.).
  • Page 104 — 220/299/300/399 Boiler Manual ® fired water boiler Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a com- plete diagnosis. Control fault indications 1. The control provides diagnostic infor- 2. Figure 100 shows the screen behavior 3.
  • Page 105 — 220/299/300/399 Boiler Manual ® fired water boiler Troubleshooting (continued) RESET TO FACTORY DEFAULT 2. Reset to Factory Default can be found on the BOILER 1. Selecting this will prompt the user to hold the enter button SETTINGS menu, see Figure 75, page 76. for a specified length of time.
  • Page 106 — 220/299/300/399 Boiler Manual ® fired water boiler Troubleshooting (continued) Figure 102 ® boilers — Fault displays, diagnostics and corrective actions Evergreen Troubleshooting suggestions for Condition Diagnostics Corrective Action(s) Display Nothing shown Control is not receiving 24V Check wiring for short circuit or Correct wiring per wiring diagram including connection of transformer on display power.
  • Page 107 Manual reset is required if the Inspect vent system for abnormal wear or damage. temperature rises above 220° F. Reset using manual reset screen Contact Weil-McLain Technical Support. on display. – 107 – Part number 550-100-131/0120...
  • Page 108 — 220/299/300/399 Boiler Manual ® fired water boiler Troubleshooting (continued) Figure 104 ® boilers — Fault displays, diagnostics and corrective actions Evergreen Troubleshooting suggestions for Condition Diagnostics Corrective Action(s) Display Occurs if manual or automatic Automatic external limit will Is there an external safety device connected? If yes, trouble shoot the LIMIT OPEN reset limit opens.
  • Page 109 — 220/299/300/399 Boiler Manual ® fired water boiler Troubleshooting (continued) Figure 105 ® boilers — Fault displays, diagnostics and corrective actions Evergreen Troubleshooting suggestions for Condition Diagnostics Corrective Action(s) Display IGNITION Boiler went through 5 ignition Automatically resets after 1 hour Check condensate trap for blockage allowing condensate to accumulate FAULT attempts and never detected...

  • Page 110: Maintenance

    This is particularly important if the boiler is 1. Isolate the boiler from the heating system. located in the same room as other appliances. 2. Obtain Sentinel X400 cleaner from Weil-McLain. Follow Inspect boiler jacket door gaskets. Gaskets instructions supplied with the cleaner to clean the boiler must be in good condition, with no tears or heat exchanger.

  • Page 111: Cleaning Heat Exchanger Flue Side

    — 220/299/300/399 Boiler Manual ® fired water boiler Cleaning heat exchanger flue side The boiler contains ceramic fiber materials. Use Figure 106 Remove the burner access panel and screws care when handling these materials per instructions (1 and 3) and air baffle and screws (2 and 4) on page 94 of this manual.
  • Page 112 — 220/299/300/399 Boiler Manual ® fired water boiler Cleaning heat exchanger flue side (continued) Inspect combustion chamber and 4. Remove the heat exchanger cover plate: refractory a. See Figure 109, page 115 part A, part B and part C. b. Use a 10 mm wrench or socket to remove the nuts 1.
  • Page 113 — 220/299/300/399 Boiler Manual ® fired water boiler Cleaning heat exchanger flue side (continued) 5. If the vacuum cleaner is unable to clean completely, wash the Figure 107 Placing refractory into heat exchanger and heating surfaces with clean, warm water,using the following applying silicone adhesive –...
  • Page 114 — 220/299/300/399 Boiler Manual ® fired water boiler Cleaning heat exchanger flue side (continued) Reinstall components Figure 108 Legend for Figure 109, page 115 1. See Figure 109, page 115 for reference. 2. Obtain the new burner gasket (item 12) from the Maintenance Kit Boiler interior assembled view, and install into the heat exchanger cover plate.
  • Page 115 — 220/299/300/399 Boiler Manual ® fired water boiler Cleaning heat exchanger flue side (continued) Figure 109 Accessing the burner or heat exchanger (see Legend on page 114), (Evergreen ® 220 shown). – 115 – Part number 550-100-131/0120...

  • Page 116: Replacement Parts

    Replacement parts must be purchased through a local disassembling parts of the boiler. Failure to replace Weil-McLain distributor. When ordering, specify boiler model damaged components and to use only the parts spe- and size and include description and part number of replace- ment part.
  • Page 117 (2 required) (EVG 220) – 3” Kit 383-500-397 (EVG 220, 299, 300 & 399) – 4” Kit 383-500-398 Protonode Conversion Kit –Bacnet 383-600-322 Go to www.weil-mclain.com to locate Weil-McLain distributors – 117 – Part number 550-100-131/0120...
  • Page 118 562-248-762 Bracket mounting heat exchanger (Includes screws) 383-900-087 Panel - burner access (Includes hardware) 383-900-041 Pressure switch Set point 3.25 W.C. 383-900-080 Tube - pressure switch 590-300-056 Go to www.weil-mclain.com to locate Weil-McLain distributors – 118 – Part number 550-100-131/0120...
  • Page 119 220/299/300/399 (see Figure 112, page 118 for part numbers) Jacket assembly — Evergreen Gasket shown is provided in Item 130, pages 121 and 123 Gasket Kit P/N 383-900-028 Go to www.weil-mclain.com to locate Weil-McLain distributors – 119 – Part number 550-100-131/0120...
  • Page 120 Heat exchanger water temperature sensor (2 required) 511-724-296 temperature) Burner access cover, seal and hardware (Includes item 280) 383-900-019 Burner access cover seal, burner gasket and hardware 383-900-010 Go to www.weil-mclain.com to locate Weil-McLain distributors – 120 – Part number 550-100-131/0120...
  • Page 121 — 220/299/300/399 Boiler Manual ® fired water boiler Replacement parts (continued) Figure 115 ® 220 heat exchanger assembly (see Figure 114, page 120 for part numbers) Evergreen Go to www.weil-mclain.com to locate Weil-McLain distributors – 121 – Part number 550-100-131/0120...
  • Page 122 — 220/299/300/399 Boiler Manual ® fired water boiler Replacement parts (continued) Figure 116 ® 299/300/399 (see Figure 117, page 123 for illustration) Heat exchanger parts Evergreen Model Model Description / contents Part Number Item Name 299/300 383-900-024 — Heat exchanger, gaskets and hardware (Includes items 130, and 150) 383-900-023 —...
  • Page 123 — 220/299/300/399 Boiler Manual ® fired water boiler Replacement parts (continued) Figure 117 ® 299/300/399 heat exchanger assembly (see Figure 116, page 122 for part numbers) Evergreen – 123 – Part number 550-100-131/0120...
  • Page 124 383-500-095 — 30 PSIG relief valve — Relief valve shipped loose for field installation 383-900-076 — — 540-131-075 — — Condensate drain trap (not shown) 540-131-076 — Go to www.weil-mclain.com to locate Weil-McLain distributors – 124 – Part number 550-100-131/0120...
  • Page 125 — 220/299/300/399 Boiler Manual ® fired water boiler Replacement parts (continued) Figure 119 ® 220/299/300/399 (see Figure 118, page 124 for part numbers) Piping components for Evergreen Go to www.weil-mclain.com to locate Weil-McLain distributors – 125 – Part number 550-100-131/0120...
  • Page 126 Cover ground terminal kit (not shown) 383-900-098 Gasket - flue temperature sensor 590-318-011 Circulator Evergreen 220/299/300 Taco Pump 0014 511-405-133 Circulator Evergreen 399 Taco Pump 0013 511-405-140 Go to www.weil-mclain.com to locate Weil-McLain distributors – 126 – Part number 550-100-131/0120...
  • Page 127 — 220/299/300/399 Boiler Manual ® fired water boiler Replacement parts (continued) Figure 121 ® 220/299/300/399 (see Figure 120, page 126 for part numbers) Controls & electrical assemblies — Evergreen Go to www.weil-mclain.com to locate Weil-McLain distributors – 127 – Part number 550-100-131/0120...

  • Page 128: Dimensions

    — 220/299/300/399 Boiler Manual ® fired water boiler Dimensions Figure 122 ® 220/299/300/399 (all dimensions in inches) Dimensional data — Evergreen LEFT RIGHT FRONT 1 Boiler supply tapping — 1½” NPT. 6 Gas connection – ¾” NPT (manual gas valve shipped 2 Boiler return tapping —...

  • Page 129: Ratings

    96.5 96.0 4.3% 4.3% 4” PVC Notes As an Energy Star Partner, Weil-McLain for requirements of the building and All vent and air pipe elbows must be sweep elbows, NOT short-radius ® 220 nothing need be added for normal has determined that Evergreen piping and pickup.

  • Page 130: Ratings - Multiple Boilers

    Based on standard test procedures outlined by DOE for individual boilers. Net water ratings are based on piping and pickup allowance of 1.15. Consult Weil-McLain Technical Services for other allowances. Total amp requirement includes up to three circulators, not exceeding 2.2 amps per circulator.

  • Page 131: Installation And Service Certificate

    — 220/299/300/399 Boiler Manual ® fired water boiler Installation and Service Certificate Boiler Data Date installed _____________________ Boiler Model / Series Evergreen ® __________ / Series _____ CP Number ________________ FUEL: Natural ______ LP ______ Btu Input ___________________ CERTIFIED THAT ❏ Installation instructions have been followed.

  • Page 132: Installation And Gas Boiler Data Collection Sheet

    — 220/299/300/399 Boiler Manual ® fired water boiler Installation and Gas Boiler Data Collection Sheet Boiler Model / Series EVG ________ / Series _______ Date Installed: ___________________ CP Number: __________________ Fuel Type: Natural___ LP___ BTU Input: ____________ Flame signal on control display at HIGH fire: _________________ Flame signal on control display at LOW fire: ____________ Was venturi changed? YES___ NO___ Was gas valve throttle adjusted? YES___ NO___...
  • Page 133 — 220/299/300/399 Boiler Manual ® fired water boiler Installation and Gas Boiler Data Collection Sheet CO2 @: High Fire______% Low Fire______% CO@: High Fire _____ ppm Low Fire _____ ppm Natural Gas / LP input rate measured: HIGH ______ CFH / LOW________ CFH Priority 4 Settings Priority 2 Settings Priority 3 Settings...
  • Page 134 — 220/299/300/399 Boiler Manual ® fired water boiler Notes – 134 – Part number 550-100-131/0120...
  • Page 135 — 220/299/300/399 Boiler Manual ® fired water boiler Notes – 135 – Part number 550-100-131/0120...
  • Page 136 — 220/299/300/399 Boiler Manual ® fired water boiler...

This manual is also suitable for:

Evergreen evg 299Evergreen evg 300Evergreen evg 399

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