Page 1 ® Series 2 Models 1000 - 2000 MBH Commercial Condensing Gas-fired water boilers 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.
Page 2 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler ® SlimFit Commercial Condensing Water Boiler Control overview SlimFit model numbers: • The control can operate a single boiler or coordinate with other Left-hand boilers (cleanout access on Right-hand boilers (cleanout access SlimFit 1000-2000 Series 2 boilers in a multiple boiler system.
Page 3 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler ® SlimFit Commercial Condensing Water Boiler (Model SF2000 shown) Electrical panel components Configuration options (Order boiler as left-hand or right-hand) Left-hand (suffix L) • Cleanout panel access is on the left side when viewed from the burner end.
Page 4: Table Of Contents
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Contents Contents DO NOT START THIS BOILER without Hazard definitions following all instructions and procedures specified in the following sections: Please read before proceeding “Startup — fill the system” on page 79 Prepare boiler location “Startup —...
Page 5: Please Read Before Proceeding
Therefore, Weil-McLain equipment contaminated with saltwater Otherwise, by operating this boiler, you will cause or polluted water will no longer be covered under warranty and...
Page 6: Prepare Boiler Location
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Prepare boiler location Installations must comply with: Figure 1 Minimum foundation size • Local, state, provincial, and national codes, laws, regulations and ordinances. Boiler model Minimum size (inches) •...
Page 7 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Prepare boiler location (continued) Clearance requirements Openings in floors, walls, ceilings or roofs must be designed for fire stopping as required by local codes. Vent pipe openings through combustible Clearances from combustible materials materials must be 3/8”...
Page 8 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Prepare boiler location (continued) Verify that boiler placement and clearances comply with all applicable codes. Placing multiple boilers 1. Locate multiple boilers in boiler room possible, provide at least the minimum 4.
Page 9 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Prepare boiler location (continued) Verify that boiler placement and clear- ances comply with all applicable codes. Figure 6 Side-by-side installation of multiple SlimFit boilers (using left-hand and right-hand boilers together) Part number 550-100-561/0224...
Page 10: Prepare Boiler
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Prepare boiler Provide air openings to room DIRECT EXHAUST — For direct exhaust installations, com- bustion air openings into the room must be sized to handle the SlimFit boiler and all other appliances.
Page 11 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Prepare boiler (continued) 2. Move the crate to a solid, level surface. Cold weather handling — If boiler has been stored in a very cold location (below 32°F) before 3.
Page 12 Weil-McLain hydrostatically pressure tests each SlimFit boiler in the factory to 1½ times maximum allowable working pressure per Boiler relief valve and P/T gauge ASME Section IV requirements.
Page 13 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Prepare boiler (continued) 5. Remove the pressure & temperature gauge from the trim box Figure 9 Hydrostatic test piping connections — shipped with the boiler. flanges, valves and gaskets provided by 6.
Page 14: Install Water Piping
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Install water piping Backflow preventer Use two wrenches when tightening water piping at boiler, using one of the wrenches to prevent the boiler interior 1. Use backflow check valve in cold water supply as re- piping from turning.
Page 15 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Install water piping (continued) DO NOT design for flow rates above or below the range listed in Figure 13. Recommended pipe sizing The boiler and system components can be damaged by excessive or insufficient Size the piping and the pumps to provide the required temperature flow.
Page 16 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Install water piping (continued) Expansion tank and make-up water Figure 14 Expansion tank piping — diaphragm-type expansion tank 1. Ensure expansion tank size will handle boiler and system water volume and temperature.
Page 17 Space heating to same Priority. Do not use outdoor reset applications. for this application. 3. For more than 3-zones, use Weil-McLain WMZV zone valve controller. Controlling the circulators 1. The control can control up to four circulators (boiler circulator Connect zone valve end switches to a Space and three others).
Page 18 Space Heating Priority – Space heating is priority over DHW. Use Priorities 1 and/or 2 for space heating; Priority 3 for DHW. The control will not run multiple priorities simultaneously. 3. For more than 3-zones, use Weil-McLain WMZV zone valve Controlling the circulators controller.
Page 19 1. The control can control up to four circulators (boiler circulator defaulted to DHW for DHW Priority applications. and three others). Refer to Field wiring, beginning on page 47, 3. For more than 3-zones, use Weil-McLain WMCR zone Circ for instructions on wiring to circulators. The boiler circulator controller.
Page 20 DHW for DHW Priority applications. b. Space Heating Priority – Space heating is priority over DHW. 3. For more than 3-zones, use Weil-McLain WMCR zone Circ Use Priorities 1 and/or 2 for space heating; Priority 3 for DHW. controller.
Page 21 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 105 for details. Chilled medium, if used, is piped in parallel with heating boiler as shown in Figure 20.
Page 22: Venting/Air Piping - Massachusetts Installations
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Venting/air piping — Massachusetts installations Venting instructions for the installations in the Commonwealth of Massachusetts (a) For all sidewall horizontally-vented gas-fueled equip- . The state or local gas inspector of INSPECTION the side wall horizontally vented gas fueled equip- ment installed in every dwelling, building or structure...
Page 23: Venting/Combustion Air - General
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Venting/combustion air — general Method 1: Direct exhaust Method 2: Direct vent There are two venting methods available. • Combustion air taken from inside • Combustion air piped to boiler from Follow the instructions (no air piping connected to air outside...
Page 24 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Venting/combustion air — general (continued) Combustion air contamination Direct exhaust Direct vent (combustion air from boiler room): (combustion air piped from outside): a. Provide combustion air openings to boiler room as a.
Page 25: Venting/Combustion Air - Options (Category Ii & Iv)
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Venting/combustion air — options (Category II & IV) Figure 22 Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet local codes (see Figure 96, page 105 for vent/air part/kit numbers) Items Material...
Page 26: Appliances Remaining On An Existing Vent System
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler PVC Venting allowed per requirements specified below. Figure 23 Exhaust ONLY after 10 linear feet, the pipe and fittings can then be transitioned from CPVC to PVC. Both 5 feet lengths of pipe and fittings are...
Page 27: Venting/Combustion Air - Options (Category Ii)
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Venting/combustion air — options (Category II) Category II Requirements In addition to the SlimFit boilers Category IV The flue gas temperature should typically be within 20°F of the return water temperature of the boiler. If there is the rating (positive pressure, likely to condense), potential for a wide variation in return water temperatures, SlimFit boilers are approved for Category II...
Page 28 Weil-McLain recommends the use of a Variable Speed Chimney Fan / Power venter to ensure that the appropriate negative pressure range is kept for Category II venting. The reason this may be needed is due to the higher efficiency of the SlimFit boiler.
Page 29 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Venting/combustion air — options Figure 24 SlimFit boiler venting and air piping — OPTIONS and PIPING LIMITS — The table below lists the acceptable vent/air pipe terminations described in this manual. USE ONLY the pipe materials listed in Figure 22, page 25 See Figure 96, page 105 for part/kit numbers Boiler vent and air connections:...
Page 30: Direct Exhaust - Boiler Room Air Openings (Category Iv)
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler DIRECT EXHAUST — Boiler room air openings (Category IV) Special considerations Combustion air provision The SlimFit Commercial boiler can use inside air if no contami- Tight construction nants are present in the boiler space.
Page 31 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIRECT EXHAUST — Boiler room air openings (continued) (Category IV) Figure 25 MINIMUM combustion air openings for direct exhaust applications — ALL OPENING SIZES ARE FREE AREA Air openings SlimFit boiler SlimFit boiler...
Page 32: Direct Exhaust - Termination Location (Category Iv)
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler DIRECT EXHAUST — Termination location (Category IV) Figure 26 DIRECT EXHAUST INSTALLATIONS — Requirements for termination location — clearances and placement Vent Termination Locations – the minimum distance from adjacent public walkways, adjacent build- ings, openable windows and building openings shall not be less than those values specified in the National Fuel Gas Code - ANSI Z223.1/NFPA54 –...
Page 33: Direct Exhaust - Sidewall (Category Iv)
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIRECT EXHAUST — Sidewall (Category IV) Figure 27 Sidewall direct exhaust termination Use only the vent materials and kits listed in Figure 22, page 25. Read and follow all instructions in this manual.
Page 34 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler DIRECT EXHAUST — Sidewall (continued) (Category IV) 2. Vent pipe penetration: Figure 28 Multiple boiler direct exhaust sidewall a. Cut a hole for the vent pipe. terminations (see Figure 27, page 33 for b.
Page 35: Direct Exhaust - Vertical (Category Iv)
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIRECT EXHAUST — Vertical (Category IV) Figure 30 Vertical direct exhaust termination Use only the vent materials and kits listed in Figure 22, page 25. Read and follow all instructions in this manual.
Page 36: Direct Vent - Boiler Room Air Openings (Category Iv)
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler DIRECT VENT — Boiler room air openings (Category IV) Combustion/ventilation air provision Exhaust fans and air movers The appliance space must never be under a negative pressure For direct vent installations, combustion air must be ducted unless all appliances are installed as direct vent.
Page 37 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIRECT VENT — Boiler room air openings (continued) (Category IV) Figure 32 MINIMUM combustion air openings for direct vent applications — ALL OPENING SIZES ARE FREE AREA Air openings SlimFit boiler SlimFit boiler...
Page 38: Direct Vent - Termination Location
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler DIRECT VENT — Termination location (Category IV) Figure 33 DIRECT VENT INSTALLATIONS — Requirements for termination location — clearances and placement Vent Termination Locations – the minimum distance from adjacent public walkways, adjacent build- ings, openable windows and building openings shall not be less than those values specified in the National Fuel Gas Code - ANSI Z223.1/NFPA54 –...
Page 39: Direct Vent - Sidewall (Category Iv)
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIRECT VENT — Sidewall (Category IV) Figure 34 Sidewall direct vent terminations — vent and air Use only the vent/air materials and kits listed in Figure 22, page 25. Read and follow all instructions in this manual.
Page 40 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler DIRECT VENT — Sidewall (continued) (Category IV) 3. Vent pipe penetration: Figure 36 Multiple terminations — clearance from a. Cut a hole for the vent pipe. vent of one to air intake of the next b.
Page 41: Direct Vent - Vertical (Category Iv)
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIRECT VENT — Vertical (Category IV) Figure 38 Vertical direct vent terminations (air termination can be vertical or sidewall as shown below). Use only the vent/air piping materials and kits listed in Figure 22, page 25.
Page 42 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler DIRECT VENT — Vertical (continued) (Category IV) Install vent and air terminations Figure 39 Vertical vent and air terminations. 1. Air pipe penetration a. Cut a hole for the air pipe, sized per the vent/air pipe manufacturer’s instructions.
Page 43 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIRECT VENT — Vertical (continued) (Category IV) Figure 41 Termination location — multiple boilers — vertical vent/sidewall air. VENT PIPING (through roof) AIR PIPING (sidewall) Multiple boiler applications —...
Page 44: Install Condensate Components
Condensate from the SlimFit boiler will be slightly acidic (typically with a pH from 3.2 to 4.5). Install a neutralizing filter if required by local codes. See Replacement parts section at the end of this manual for a Weil-McLain con- densate neutralizer kit. Figure 46...
Page 45: Gas Piping
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Gas piping DO NOT connect the SlimFit boiler to a propane sup- Use two wrenches when tightening ply. The boiler is suitable for firing ONLY natural gas. Failure to comply could result in severe personal injury, gas piping at boiler , using one wrench...
Page 46: Gas Train Diagram
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Gas piping (continued) Pipe sizing Figure 49 Pipe capacity for natural gas 1. Size gas supply piping from meter outlet to entrance of boiler in accordance with Figure 49 and Figure 50. Gas supply pipe capacity (cubic feet per hour) 2.
Page 47: Field Wiring (See Figure 52 & Figure 53)
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Field wiring (see Figure 52 & Figure 53) Wiring must be N.E.C. Class 1. If original wir- ELECTRICAL SHOCK HAZARD — For ing as supplied with boiler must be replaced, your safety, turn off electrical power sup- use only type 105 °C wire or equivalent.
Page 48 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Field wiring Schematic Diagram (continued) Figure 52 Schematic wiring diagram — SlimFit boilers (continued on next page) Part number 550-100-561/0224...
Page 49 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Field wiring Schematic Diagram (continued) Figure 57 (continued from previous page) Schematic wiring diagram — SlimFit boilers Part number 550-100-561/0224...
Page 50 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Field wiring Ladder Diagram (continued) Figure 53 Ladder wiring diagram — SlimFit boilers (continued on next page) Part number 550-100-561/0224...
Page 51 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Field wiring Ladder Diagram (continued) Figure 53 (continued from previous page) Ladder wiring diagram — SlimFit boilers Part number 550-100-561/0224...
Page 52 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Field wiring (see Figure 52 & Figure 53) (continued) A. 120 VAC Power Supply – REQUIRED Terminal Block P1 1. Boiler line voltage power — Boiler loads are listed below. Provide and install a fused disconnect or service switch as required by applicable codes.
Page 53 SlimFit boiler to ensure proper flow through the heat exchanger. Other designed piping arrangements will work as long as water flow requirements are met from page 15, contact your local Weil-McLain commercial representative for assistance. See Figure 52, page 48 for details D 24 VAC Inputs 1, 2 and 3 (tstats, end switches, etc ) –...
Page 54 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Field wiring (see Figure 52 & Figure 53) (continued) E System supply and return temperature sensors – REQUIRED Terminal Block P14 #1 & #2 1. Two strap-on temperature sensors are shipped with each boiler. Attach one to the system supply piping and the other to the system return piping.
Page 55 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Field wiring (see Figure 52 & Figure 53) (continued) G. External limits – OPTIONAL To cause MANUAL reset: Terminal Block P13 #1 & #2 SlimFit control will require manual reset after circuit is interrupted 1.
Page 56 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Field wiring (see Figure 52 & Figure 53) (continued) I. Closure switch (flow switch and/or CAD) – OPTIONAL Jumper on Terminal Strip P11 1. A flow switch or combustion air damper (CAD) interlock can be configured by removing jumper.
Page 57 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Field wiring (see Figure 52 & Figure 53) (continued) J. 0 –10 VDC Remote TARGET input – OPTIONAL Terminal Block P15 #5 & #6 1. See illustration at right and Figure 52, page 48 (wiring diagram) for details.
Page 58 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Field wiring (see Figure 52 & Figure 53) (continued) K. 0–10 VDC Remote MODULATION input – OPTIONAL Terminal Block P15 #5 & #6 (SlimFit control module, left side) —...
Page 59 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Field wiring (see Figure 52 & Figure 53) (continued) L. Multiple Boiler and BMS Connections – see ADVANCED Manual Terminal Strips EP11 and E P12 on Expansion Module (Expansion module, right side) 1.
Page 60: Zoning With The Slimfit Control
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Zoning with the SlimFit Control A. Zoning with CIRCULATORS, suggested applications Three space heating zones (no DHW) 1. Review wiring information on page 49 (120VAC out- puts) and page 53 (24VAC inputs). 2.
Page 61 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Zoning with the SlimFit Control (continued) B. Zoning with ZONE VALVES, suggested applications Two space heating zones (no DHW) 1. Review wiring information on page 49 (120VAC outputs) and page 53 (24VAC inputs).
Page 62: Control Operation And Setup
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Control operation and setup Figure 54 Control sequence of operation Control setup Display Control action status 1. Set control parameters using the WIZARD option provided on initial (Also see Figure 58, page 66) text start-up or manually enter parameters using control menus (see...
Page 63 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Control operation and setup (continued) Control Priorities & Input/Outputs Setting Up the Boiler • For heating installations with multiple systems, the Control uses • DETERMINE input/output needs – PRIORITIES to determine the order of operation of the systems.
Page 64 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Control operation and setup (continued) Outdoor reset operation Figure 55 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 55.
Page 65 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Control operation and setup (continued) Figure 57 SlimFit single boiler essential settings (REQUIRED on initial start-up) — see page 67 for explanation Part number 550-100-561/0224...
Page 66 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Control operation and setup Control operation and setup (continued) (continued) Figure 58 SlimFit control display screens and typical navigation Part number 550-100-561/0224...
Page 67 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Control operation and setup (continued) Figure 59 SlimFit 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 68: Contractor Menus
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler CONTRACTOR menus Boiler Model, Altitude and Fuel Type are 1. Access contractor menus by pressing and holding the UP and critical settings Failure to set correctly could DOWN arrow keys at the same time for 7 seconds.
Page 69 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler BOILER SETTINGS menu, BASIC mode Boiler Model, Altitude and Fuel Type are 1. Access contractor menus by pressing and holding the UP and critical settings Failure to set correctly could DOWN arrow keys at the same time for 7 seconds.
Page 70: Priority 1, 2, 3 Menus, Basic Mode
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler PRIORITY 1, 2, 3 menus, BASIC mode Boiler Model, Altitude and Fuel Type are 1. Access contractor menus by pressing and holding the UP and Failure to set correctly could DOWN arrow keys at the same time for 7 seconds.
Page 71: Assign Inputs Menu, Basic Mode
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler ASSIGN INPUTS menu, BASIC mode Boiler Model, Altitude and Fuel Type are 1. Access contractor menus by pressing and holding the UP and critical settings Failure to set correctly could DOWN arrow keys at the same time for 7 seconds.
Page 72 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler ASSIGN INPUTS menu, BASIC mode (continued) Figure 65 AUX PUMP/OUTPUT operation (accessed in ASSIGN INPUTS menu – see Figure 64, page 71) Option Activation conditions Suggested uses •...
Page 73: Diagnostic Menu
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIAGNOSTIC menu Figure 67 DIAGNOSTICS menu navigation (see Figure 58, page 66 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 74 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler DIAGNOSTICS menu (continued) Figure 68 DIAGNOSTICS menu navigation, continued (see Figure 58, page 66 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 75 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIAGNOSTICS menu (continued) Figure 69 DIAGNOSTICS menu details (see Figure 58, page 66 for access information) Menu/Item Comment Temperatures Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfied, post purge, Warm Status Weather Shut down, Trouble Boiler Out1...
Page 76 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler DIAGNOSTICS menu (continued) Figure 70 DIAGNOSTICS menu details (continued) (see Figure 58, page 66 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 77 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler DIAGNOSTICS menu (continued) Figure 71 DIAGNOSTICS menu details (continued) (see Figure 58, page 66 for access information) Menu/Item Comment Displays time that lockout occurred Time Date Displays date that lockout occurred Displays what the status of the boiler was at the time of the error Status Temperatures...
Page 78: Maintenance, Date And Time Menus
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler MAINTENANCE, DATE AND TIME menus Figure 72 MAINTENANCE, DATE AND TIME menus — navigation (see Figure 58, page 66 for access information) Comment Maintenance Info Name Contractor name to appear in maintenance reminders and during lockouts Phone Contractor phone number Model...
Page 79: Startup - Fill The System
Startup — fill the system Clean system to remove sediment Antifreeze with Inhibitor Use only antifreeze listed by Weil-McLain as suit- You must thoroughly flush the system (without able for use with SlimFit Gas Boilers. See additional boiler connected) to remove sediment. The high-...
Page 80 Add inhibitor as needed to bring to acceptable level, using the antifreeze products listed in this document only inhibitor test kit to verify. for use in Weil-McLain SlimFit boilers. Do not apply these products or instructions for other applications. •...
Page 81: Startup - Final Checks
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Startup — final checks Check thermostat circuit(s) Figure 73 Pressure switches 1. Disconnect the two external wires connected to the boiler thermostat terminals (see instructions beginning on page 47 Y-fitting with WHITE hoses to top of switches for terminal locations).
Page 82: Startup Procedure
“Check flame & For elevations above 10,000 feet, please contact combustion with instruments, page 82.” Weil-McLain Technical Support for details. 2. Boiler behavior that might indicate a need to check combus- In Canada, Input rates are derated 10% for alti- tion values at high fire (as per page 82) to verify boiler is in tudes of 2000 ft.
Page 83 Figure 75, follow the screw when completed. procedure given for adjusting the throttle 6. Consult your local Weil-McLain representative if acceptable results screw on the gas valve. If throttle screw cannot be obtained for both high and low fire.
Page 84 2. Use the Control display to navigate to Manual test mode (see Figure 68, page 74) and force the firing rate to Low (low fire). Weil-McLain? 3. Look at the flame through the flame inspection window. The Return instructions to envelope and give to owner low fire flame should be stable and evenly distributed over burner surface with a uniform orange color.
Page 85 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Startup procedure (continued) Figure 78 Operating instructions (WARNING — Verify that the control is set correctly before proceeding Part number 550-100-561/0224...
Page 86: Annual Startup And Maintenance Schedule
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Annual startup and maintenance schedule Figure 79 Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see SlimFit User’s Information Manual for instructions) General: Investigate reported problems.
Page 87: Annual Startup
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Annual startup FIRST - YEAR SPECIAL HANDLING CERAMIC FIBER MATERIALS INSPECTION REMOVAL OF SIGHT GLASS GASKET No later than 12 months after the boiler is in- stalled, perform a first-year inspection of the boiler. The sight glass gasket in this product in addition to This must include the following...
Page 88 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Annual startup (continued) Figure 80 Air inlet box screen The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service techni- cian.
Page 89 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Annual startup (continued) Check water system • Open-type — located above highest radiator or baseboard unit, usually in the attic or closet. Has a 1. Verify all system components are correctly installed and gauge glass and overflow pipe to a drain.
Page 90 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Annual startup (continued) Figure 81 Gas valve and venturi Check ignition wiring 1. Check ignition cable electrical resistance. A good cable will have resistance between 900 and 1000 ohms. Replace if not acceptable.
Page 91 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Annual startup (continued) Perform startup procedure per manual Figure 84 Combustion chamber access cover removal 1. Perform all startup procedures on pages page 82 through page 85. Check burner flame 1.
Page 92 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Annual startup (continued) Check flue gas temperature c. Insert burner into machined pocket on end sec- tion, burner should tilt down slightly as the end of 1. Set the boiler to high fire. Then adjust the control module display the burner rests on opposite end section.
Page 93: Troubleshooting
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING. VERIFY PROPER OPERATION AFTER SERVICING. Before servicing and making connections . ELECTRICAL SHOCK HAZARD — The boiler ON/OFF switch does not turn off all power to ALWAYS TURN POWER OFF TO THE TURN OFF ALL POWER TO THE the boiler.
Page 94 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Troubleshooting (continued) Do not jumper fuse or replace with any fuse except Check the following: as specified. Failure to comply could result in severe personal injury, death or substantial property dam- 1.
Page 95 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a complete diagnosis. Control fault indications 1. The Control provides diagnostic information for below the display illustration lists manual reset conditions and how to both automatic reset conditions and manual reset reset from them.
Page 96 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Troubleshooting (continued) Figure 92 Troubleshooting suggestions for SlimFit boilers 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 62, page 69.
Page 97 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Troubleshooting (continued) Figure 92 Troubleshooting suggestions for SlimFit boilers (continued) Control Fault Displays, Diagnostics and Suggested Corrective Actions Display Condition Diagnostics Corrective Action(s) Control is not receiving 24V Check wiring for short circuit or Correct wiring per wiring diagram including connection of transformer to the Nothing shown...
Page 98 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Troubleshooting (continued) Figure 92 Troubleshooting suggestions for SlimFit boilers (continued) Control Fault Displays, Diagnostics and Suggested Corrective Actions Display Condition Diagnostics Corrective Action(s) LOW WTR Occurs if internal low water Automatic reset occurs if contacts Check for low water condition in system.
Page 99 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Troubleshooting (continued) Figure 92 Troubleshooting suggestions for SlimFit boilers (continued) Display Condition Diagnostics Corrective Action(s) Occurs if manual or automatic Automatic external limit will reset Is there an external safety device connected? If yes, trouble shoot the external LIMIT OPEN reset limit opens.
Page 100 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Troubleshooting (continued) Figure 92 Troubleshooting suggestions for SlimFit boilers (continued) Display Condition Diagnostics Corrective Action(s) Boiler went through 5 ignition Automatically resets after 1 hour or Check condensate trap for blockage allowing condensate to accumulate inside IGNITION heat exchanger.
Page 101 2 ½ minutes. flue-ways for abnormal wear and buildup. Manual reset is required if the temperature rises above 220°F. Inspect vent system for abnormal wear or damage. Reset using manual reset screen on display. Contact Weil-McLain Technical Support. Part number 550-100-561/0224...
Page 102: Maintenance
Inspect cleanout plate gasket exchanger life. 1. Inspect the cleanout plate gasket (Figure 93, page 103). 4. Weil-McLain recommends Sentinel X400 for cleaning boiler. Replace if damaged. See the Repair Parts section at the end of this manual for ordering information.
Page 103 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Maintenance (continued) Figure 93 Cleanout plate removal/re-installation Figure 94 Using the cleaning tool Silicone cord must start/end at top center, add a dap of silicone over joint. 45°...
Page 104 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Maintenance (continued) Figure 95 Cleanout plate nut tightening sequences the cleanout Gradually tighten plate nuts in the sequence shown in Figure 95 until torque reaches 18 N-m/160 in- lbs/13 ft-lbs.
Page 105: Replacement Parts
— Boiler Manual commercial condensing gas fired water boiler Replacement parts Go to www.weil-mclain.com to locate Weil-McLain distributors Replacement parts must be purchased through Weil-McLain part numbers are found in Weil- a local Weil-McLain distributor. When ordering, McLain Boilers and Controls Repair Parts Lists.
Page 106 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors Vent/air piping components Vent Manufacturer Vent Type Adapter Description Vent Mfr’s P/N Centrotherm InnoFlue SW Polypropylene Tapered 10” to 6” reducer ISTR1006 Tapered 10”...
Page 107 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Replacement parts (continued) Figure 98 Jacket parts Part number 550-100-561/0224...
Page 108 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors Figure 99 Heat exchanger Item Description Part Number Silicone cord, 10 mm x 100 meters 383-600-201 Cleanout plate gasket kit, SF1000 (gasket, silicone sealing cord, hardware)
Page 109 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Replacement parts (continued) Figure 100 Heat exchanger 240 250 260 380 390 400 350 360 370 270 280 290 180 190 200 300 310 320 110 120 130 160 170 140 150 SF7011...
Page 110 ® — Boiler Manual commercial condensing gas fired water boiler Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors Figure 101 Burner, blower, venturi and gas train Item Description Part Number Piping end combustion chamber access plate kit (plate, gasket, insulation, hardware) (Not shown)
Page 111 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Replacement parts (continued) Figure 102 Burner, blower, venturi and gas train 110 120 130 170 180 190 340 350 320 330 200 210 220 390 400 410 230 270 280 420 430 440 290 300 310...
Page 112 Flue temperature sensor gasket 590-318-011 Fuse 3-amp, fast-blow ATO (5 fuses) (not shown) 383-500-603 Fuse 12-amp 250-Volt fast-blow AG (5 fuses) (not shown) 383-500-604 Igniter Cable (COFI) (not shown) 384-000-310 Go to www weil-mclain com to locate Weil-McLain distributors Part number 550-100-561/0224...
Page 113 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Replacement parts (continued) Figure 104 Controls Part number 550-100-561/0224...
Page 114: Dimensions
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Dimensions Figure 105 LEFT-HAND Dimensional data — configuration LEGEND Supply connection, 3” flanged Flue connection, 10” nominal Relief valve connection, 1½” NPT Return connection, 3” flanged Air connection, 10” nominal P/T gauge connection, ½”...
Page 115 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Dimensions (continued) Figure 106 RIGHT-HAND Dimensional data — configuration LEGEND Supply connection, 3” flanged Flue connection, 10” nominal Relief valve connection, 1½” NPT Return connection, 3” flanged Air connection, 10”...
Page 116: Ratings - Slimfit Series 2 Boilers
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Ratings — SlimFit Series 2 boilers Figure 107 Ratings and engineering data AHRI Ratings Boiler Gross Combustion Thermal Water Vent/Air Stack/vent Boiler weight Output Input Rating Efficiency Efficiency Content Pipe Size...
Page 117: Installation And Service Certificate
SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Installation and Service Certificate Boiler Model Series CP Number Date Installed BTU Input Installation instructions have been followed. Check-out sequence has been performed. Above information is certified to be correct. Information received and left with owner/maintenance person.
Page 118: Installation And Gas Boiler Data Collection Sheet
SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler Installation and Gas Boiler Data Collection Sheet Boiler Model / Series SlimFit ________ / Series _______ Date Installed: ___________________ CP Number: __________________ Fuel Type: Natural___ BTU Input: ____________ Flame signal on control display at HIGH fire: _________________ Flame signal on control display at LOW fire: ____________ Was venturi changed? YES___ NO___...
Page 119 SlimFit ® Series 2 — Boiler Manual commercial condensing gas fired water boiler Installation and Gas Boiler Data Collection Sheet CO2 @: High Fire______% Low Fire______% CO@: High Fire _____ ppm Low Fire _____ ppm Natural Gas input rate measured: HIGH ______ CFH / LOW________ CFH Priority 4 Settings Priority 2 Settings Priority 3 Settings...
Page 120 SlimFit Series 2 ® — Boiler Manual commercial condensing gas fired water boiler WM Technologies, LLC 500 Blaine Street Michigan City, IN 46360-2388 weil-mclain.com...

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