Weil-McLain 550 MBH Nstallation And Operation Manual
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Weil-McLain 550 MBH Nstallation And Operation Manual

Weil-McLain 550 MBH Nstallation And Operation Manual

Commercial condensing gas-fired water boilers
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Series 3
Models 550 and 750 MBH
Commercial Condensing
Gas-fired water boilers
Boiler Manual
This manual must only be used by a qualified heating installer/service technician. Read all instruc-
tions, 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.
Part number 550-100-168/0516

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  • Page 1 ® Series 3 Models 550 and 750 MBH Commercial Condensing Gas-fired water boilers Boiler Manual This manual must only be used by a qualified heating installer/service technician. Read all instruc- tions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given.
  • Page 2 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER SlimFit ™ Series 3 COMMERCIAL gas-fired water boiler The control can operate a single boiler or coordinate with other SlimFit 550/750 Series 3 boilers in a multiple boiler system. Air enters the boiler enclosure through the air intake adapter (18), Control inputs and outputs allow operation of multiple heat- flows through the enclosure, enters the air inlet silencer (5), then enters...
  • Page 3 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER SlimFit ™ Series 3 COMMERCIAL gas-fired water boiler Part number 550-100-168/0516...
  • Page 4 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Contents Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Indicates presence of hazards that will cause severe personal injury, death or substantial property damage.

  • Page 5: Please Read Before Proceeding

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Please read before proceeding — The exposure of boiler components to — If any When servicing boiler — (with- Freeze protection fluids — out boiler connected) to remove sediment.

  • Page 6: Prepare Boiler Location

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler location Installations must comply with: Clearances Local, state, provincial, and national codes, laws, regulations and ordinances. National Fuel Gas Code, ANSI Z223.1 – latest edition. Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

  • Page 7: Flooring And Foundation

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler location (continued) Flooring and foundation Flooring For direct exhaust installations (com- 2. DIRECT EXHAUST — bustion air from inside), provide air openings as specified in 1.
  • Page 8 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler Vent and air piping requirements (page 20) 1. The SlimFit boiler requires a special vent system, designed Prepare boiler for propane for pressurized venting. (when required) a.
  • Page 9 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler (continued) 16. Secure the flanges together with the bolts and nuts, being 1. Locate propane orifice disc from conversion kit bag shipped careful not to over-tighten (torque to 15 N-m/132 in- with the boiler.
  • Page 10 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler (continued) See page 9 for legend is used on all SF-550 boilers, for both natural gas and propane. is used on SF-750 propane, but NOT on natural gas. MUST be installed on both the SF-550 and SF-750 to operate on propane.

  • Page 11: Perform Hydrostatic Pressure Test

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler (continued) Hydrostatic test piping connections . This is the maximum al- lowable relief valve setting for the SlimFit boiler. The boiler is shipped with a 30 PSIG relief valve. See Replacement parts in the back of this manual for alternate pressure setting relief valves.
  • Page 12 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install water piping Install relief valve Use two wrenches when tightening water piping at boiler, using one of the wrenches to prevent the boiler interior piping from turning. Failure to support the 1.

  • Page 13: System Water Piping Methods

    These designs ensure proper flow through the SlimFit boiler, for the most efficient and reliable operation of the boiler and the heating system. For other piping methods, consult your local Weil-McLain representa- tive or see separate SlimFit boiler piping guides. Recommended pipe sizing Connect minimum pipe sizing shown in Figure 4 to the supply and return connections for SF-550 and SF-750 boilers.
  • Page 14 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install water piping (continued) Expansion tank and make-up water Expansion tank piping 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Allow 7 gallons per boiler for the boiler and its piping.
  • Page 15 Use only if DHW is a zone in system. Assign DHW Priority applications. and Space heating to same Priority. Do not use outdoor 3. For more than 3-zones, use Weil-McLain WMZV zone valve reset for this application. controller. Controlling the circulators...
  • Page 16 Priority applications. b. Space Heating Priority – Space heating is priority over DHW. 3. For more than 3-zones, use Weil-McLain WMZV zone valve Use Priorities 1 and/or 2 for space heating; Priority 3 for DHW. controller. The control will not run multiple priorities simultaneously.
  • Page 17 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 50, for 3. For more than 3-zones, use Weil-McLain WMCR zone Circ instructions on wiring to circulators. The boiler circulator cannot controller.
  • Page 18 1 for DHW; Priorities 2 and/or 3 for space heating. The control will 1 is defaulted to DHW for DHW Priority applications. not run multiple priorities simultaneously. 3. For more than 3-zones, use Weil-McLain WMCR zone Circ b. Space Heating Priority – Space heating is priority over DHW. Use controller.
  • Page 19 DHW performance. Some local codes may require double-wall DHW heat exchanger design. Use only the antifreeze listed by Weil-McLain for use with this boiler. See page 109 for details. Chilled medium, if used, is piped in parallel with heating boiler as shown in Figure 11.

  • Page 20: Commonwealth Of Massachusetts

    ® — SlimFit Series 3 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 equipment . The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall installed in every dwelling, building or structure used in not approve the installation unless, upon inspection,...
  • Page 21 — Do not connect different types of piping together. — Install Dura-Vent – FasNSeal™ adapter at each boiler fitting where stainless steel pipe will be connected. Adapter is available from Dura-Vent or Weil-McLain (see page 109 for part number). Vent piping 1.

  • Page 22: Combustion Air Contamination

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — general (continued) Combustion air contamination (combustion air from boiler room): a. Provide combustion air openings to boiler room as described in this manual. DO NOT COMMON VENT b.

  • Page 23: Appliances Remaining On An Existing Vent System

    — Install Dura-Vent – FasNSeal™ adapter at each boiler fitting where stainless steel pipe will be connected. Adapter is available from Dura-Vent or Weil-McLain (see page 109 for part number). Appliances remaining on an existing vent system Do not install the SlimFit boiler into a common vent with any other appliance. This of the building.
  • Page 24 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — options Category II Requirements Table 1 Rating and Vent Data for Category II boilers Negative Pressure to be SlimFit Vent Boiler Stack / Vent maintained at Adapter required for Model...

  • Page 25: Vent Piping

    If the vent/air piping configurations covered in codes, to provide required air openings. SlimFit boiler manual cannot be applied for a particular installation, contact Weil-McLain for assistance. Other configurations may be available. Vent termination options Installations must comply with local require-...
  • Page 26 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Direct Exhaust Combustion air openings for direct exhaust 3. Caulking or sealants are applied to areas such as joints around windows and door frames, between sole plates and floors, be- Combustion and ventilation tween wall-ceiling joints, between wall panels, at penetrations air for direct exhaust boilers is provided from the...
  • Page 27 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Direct Exhaust Determine location for vertical DIRECT EXHAUST vertical termination termination 1. Locate the vent termination using the following guide- lines: 2. The vent piping must terminate in a coupling as shown in Figure 15, page 28.
  • Page 28 1. Prepare the vent termination coupling (Figure 15) by inserting a bird screen. Bird screens are not sup- plied with the SlimFit boiler. Purchase separately from Weil-McLain. 2. The vent piping must terminate in a coupling as shown in Figure 15.
  • Page 29 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Boiler room air openings Combustion air provision Special considerations The SlimFit Commercial boiler can use inside air if no contaminants are Tight construction present in the boiler space. (If contaminants are likely to be present, install ANSI Z223.1 defines unusually tight construction the boiler as a direct vent appliance, using the appropriate vent instructions where:...
  • Page 30 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Boiler room air openings (continued) MINIMUM combustion air openings for direct exhaust applications — Provisions for combustion and ventilation air to be in accordance with the section “Air for Combustion and Ventilation,”...
  • Page 31 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Sidewall Allowable vent pipe materials 1. Use only the materials listed in Figure 13, page 23. 2. Install a bird screen in each vent pipe termination (coupling or elbow). Bird screens are supplied with the boiler.
  • Page 32 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Sidewall (continued) c. The vent pipe may run up as high as 4 feet, as shown in Fig- DIRECT EXHAUST — Sidewall — ure 18 right side, with no enclosure. The vent pipe must be clearances to openings secured with braces, and maintain all required clearances.
  • Page 33 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Sidewall (continued) No closer than 48 inches below or horizontally from any DIRECT EXHAUST — Sidewall — door or window or any other gravity air inlet. termination assembly —...
  • Page 34 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Vertical Allowable vent pipe materials DIRECT EXHAUST vertical termination 1. Use only the materials listed in Figure 13, page 23. 2. Install a bird screen in each vent termination (coupling or elbow). Bird screens are supplied with the boiler.
  • Page 35 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Vertical (continued) 4. Maintain clearances as shown in the illustrations in this manual DIRECT EXHAUST — Vertical termination section. Also maintain the following: a. Vent must terminate: At least 12 inches above roof or snow line as shown in Figure 25.
  • Page 36 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Boiler room air openings Combustion/ventilation air provision Motorized air dampers If the air openings are fitted with motorized dampers, For direct vent installations, combustion air must be ducted directly from electrically interlock the damper to: outside to the SlimFit boiler air intake fitting.
  • Page 37 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Boiler room air openings (continued) MINIMUM combustion air openings for direct vent applications — Provisions for combustion and ventilation air to be in accordance with the section “Air for Combustion and Ventilation,”...
  • Page 38 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Sidewall Allowable vent/air pipe materials 1. Use only the materials listed in Figure 13, page 23. 2. Install a bird screen in each vent and air pipe termination. Bird screens are supplied with the boiler.
  • Page 39 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Sidewall (continued) b. Apply the configuration on the right side of Figure 30 when Sidewall termination with separate pipes the terminations need to be raised higher to meet clearance to —...
  • Page 40 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Sidewall (continued) d. Avoid possibility of accidental contact of flue products with Multiple terminations — separate pipes — people or pets. clearance from vent of one to air intake of e.
  • Page 41 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Sidewall (continued) Prepare wall penetrations DIRECT VENT — Sidewall — termination assembly (all parts by installer, except the 1. Air pipe penetration: bird screens) a.
  • Page 42 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Vertical Allowable vent/air pipe materials 1. Use only the materials listed in Figure 13, page 23. 2. Install a bird screen in each vent and air pipe termination. Bird screens are supplied with the boiler.
  • Page 43 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Vertical (continued) b. The flue products will form a noticeable plume as they con- Vertical termination — separate pipes dense in cold air. Avoid areas where the plume could obstruct window views.
  • Page 44 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Vertical (continued) Bird screens are supplied with the boiler. Cut to size if necessary Termination location — separate pipes — to fit vent pipe size used. terminations for multiple boilers 2.
  • Page 45 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install vent/air piping — from termination to boiler Complete termination preparation Boiler vent and air connections 1. Install vent and air terminations before proceeding. See previous pages for instructions. Pipe joint preparation and sealing 1.
  • Page 46 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install condensate components Install condensate drain tee Condensate drain tee assembly 1. See Figure 41. 2. Remove PVC fittings and gasket from the acces- sories bag. 3. Deburr and chamfer outside and inside of 1” PVC nipple (item 1) to ensure even cement distribution when joining.
  • Page 47 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 the Weil-McLain kit. For a condensate pump equipped with an Condensate pump capacity, GPH overflow switch, the switch can be connected...

  • Page 48: Gas Piping

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Gas piping Connecting gas supply piping 1. Remove jacket front panel. See Figure 46 to connect gas supply , using one wrench pipe to the boiler. a. Install a union for servicing, when required. to prevent the boiler gas line connection b.

  • Page 49: Propane Gas

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Gas piping (continued) Natural gas supply pressure Common gas line for multiple boilers 1. Pressure required at gas pressure tap near boiler gas connection (see Figure 46, page 48): a.
  • Page 50 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring Wire entrances — For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Wire entrances Failure to do so can cause severe personal injury or death.
  • Page 51 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) A. 120 VAC Power Supply – REQUIRED (control panel, left side) 1. Boiler line voltage power — Boiler load is 18 amps. Provide and install a fused disconnect or service switch (25- or 30-ampere rated recommended) as required by applicable codes.
  • Page 52 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) – REQUIRED (Expansion module, top right) 1. Provides 120 VAC Dry Contact for boiler circulator. 2. Terminals are: 1 (H), 2 (H). 3. Maximum load: 10 amps (use relay if circulator load is higher). 4.
  • Page 53 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) – REQUIRED (SlimFit control module, left side) 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. For piping larger than 5 inch diameter or nonmetallic piping, using immersion SlimFit sensors will provide faster response.
  • Page 54 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) G. External limits – OPTIONAL MANUAL (SlimFit control module, left side) 1. Remove factory-installed jumper and connect isolated contacts of external limits across P13 pins 1 and 2 to cause the control to enter manual reset lock- out if the limit circuit opens.
  • Page 55 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) I. Proof of closure (flow switch and/or CAD) – OPTIONAL (SlimFit control, bottom left of center) 1. A flow switch or combustion air damper (CAD) interlock can be config- ured by clipping the purple wire attached to Pin 3 of P7 such that there is sufficient room to strip ends and connect to field wiring.
  • Page 56 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) J. 0 –10 VDC Remote TARGET input – OPTIONAL (SlimFit control module, left side) 1. See illustration at right and Figure 52, page 60 (wiring diagram) for details. 2.
  • Page 57 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) K. 0–10 VDC Remote MODULATION input – OPTIONAL (SlimFit control module, left side) — Remote modula- tion using an external controller only works with each boiler set up as a SINGLE boiler in the SlimFit Control setup.
  • Page 58 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) M. Multiple Boiler and BMS Connections – see ADVANCED Manual (Expansion module, right side) 1. The boiler control is capable of multiple boiler communication and control of up to eight boilers in one installation.
  • Page 59 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Notes Part number 550-100-168/0516...
  • Page 60 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) Schematic wiring diagram — SF-550 & SF-750 (continued on next page) Part number 550-100-168/0516...
  • Page 61 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) (continued from previous page) Schematic wiring diagram — SF-550 & SF-750 Part number 550-100-168/0516...
  • Page 62 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) Ladder wiring diagram — SF-550 & SF-750 (continued on next page) Part number 550-100-168/0516...
  • Page 63 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) (continued from previous page) Ladder wiring diagram — SF-550 & SF-750 Part number 550-100-168/0516...
  • Page 64 ® — SlimFit Series 3 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 60 (120VAC out- puts) and page 52 (24VAC inputs). 2.
  • Page 65 ® — SlimFit Series 3 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 60 (120VAC outputs) and page 52 (24VAC inputs).

  • Page 66: Control Setup

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup Control sequence of operation Control setup 1. Set control parameters using the WIZARD option provided on initial start-up or manually enter parameters using control menus (see Figure 61, page 72 and following pages for information.) (Also see Figure 58, page 70) 2.

  • Page 67: Control Operation

    ® — SlimFit Series 3 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 PRIORITIES to determine the order of operation of the systems. The control’s MAX and MIN time settings determine the maxi- Step 1 mum and minimum times a system will be operated before being...
  • Page 68 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup (continued) Outdoor reset operation 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 69 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup (continued) SlimFit single boiler essential settings ( on initial start-up) — see page 71 for explanation Part number 550-100-168/0516...
  • Page 70 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup Control operation and setup (continued) (continued) SlimFit control display screens and typical navigation Part number 550-100-168/0516...
  • Page 71 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup (continued) SlimFit control settings available in BASIC MODE (see Advanced Manual for ADVANCED MODE settings) Boiler Model Inputs Assigned (non-selectable) Control Type System Type Priority 1, 2 or 3 High Altitude Target Mod Sensor (non-selectable)
  • Page 72 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER CONTRACTOR menus 1. Access contractor menus by pressing and holding the UP and 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 73 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER BOILER SETTINGS menu, BASIC mode 1. Access contractor menus by pressing and holding the UP and 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 74 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER PRIORITY 1, 2, 3 menus, BASIC mode 1. Access contractor menus by pressing and holding the UP and 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 75 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER ASSIGN INPUTS menu, BASIC mode 1. Access contractor menus by pressing and holding the UP and 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 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER ASSIGN INPUTS menu, BASIC mode (continued) AUX PUMP/OUTPUT operation (accessed in ASSIGN INPUTS menu – see Figure 64, page 75) Hot loop for seasonal boilers that are manually Output is always energized whenever the control is powered.

  • Page 77: Diagnostic Menu

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTIC menu menu navigation (see Figure 58, page 70 for access information) Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data DIAGNOSTICS TEMPERATURES STATUS:...
  • Page 78 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) menu navigation, continued (see Figure 58, page 70 for access information) 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 79 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) menu details (see Figure 58, page 70 for access information) Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfied, post purge, Warm Weather Shut down, Trouble Temperature of the first sensing element of the boiler’s heat exchanger outlet sensor Temperature of the second sensing element of the boiler’s heat exchanger outlet sensor...
  • Page 80 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) menu details (continued) (see Figure 58, page 70 for access information) Displays cumulative time the burner has been active (can be increased by user) Records the days of operation passed from the last time the Master boiler rotated the firing sequence.
  • Page 81 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) menu details (continued) (see Figure 58, page 70 for access information) Displays time that lockout occurred Displays date that lockout occurred Displays what the status of the boiler was at the time of the error Choose this to view the Boiler Temperatures at the time of the error Choose this to view the status of the Boiler Inputs at the time of the error Choose this to view the status of the Boiler Outputs at the time of the error...

  • Page 82: Set Time And Date

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER MAINTENANCE, DATE AND TIME menus menus — navigation (see Figure 58, page 70 for access information) Name Contractor name to appear in maintenance reminders and during lockouts Phone Contractor phone number Model...

  • Page 83: Water Chemistry

    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 SlimFit Gas Boilers. A list of approved antifreeze connected) to remove sediment.
  • Page 84 . Use only freeze-prevention fluids recommended 10. Open automatic air vent (diaphragm-type or bladder-type expansion by Weil-McLain for application in Slim- tank systems only) one turn. Fit Boiler systems. 11. Starting on the lowest floor, open air vents one at a time until water squirts out.

  • Page 85: Check For Gas Leaks

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Startup — final checks 4. Replace the flue inspection plug. Check for gas leaks The condensate trap must be filled with water during all times of boiler operation to avoid Before starting the boiler, and during initial opera- flue gas emission from the condensate drain tion, use a leak detector or smell near the floor and...
  • Page 86 Weil-McLain represen- ❏ tative. Throttle screw adjustment must Check gas piping be done only by a qualified technician,...

  • Page 87: Gas Valve Adjustment Procedure

    See Figure 74 to adjust if necessary. Re-install the cover screw when completed. b. Remove the blue cover on the throttle screw opening with 6. Consult your local Weil-McLain representative if acceptable a straight-bit screwdriver. results cannot be obtained for both high and low fire.

  • Page 88: Operating Instructions

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Operating Instructions Operating instructions (WARNING — Verify that the Control is set for the correct boiler model before proceeding Part number 550-100-168/0516...
  • Page 89 ❏ Fill out the warranty registration card and send to ting of the high gas pressure switch. Failure to comply Weil-McLain. could result in shutdown by the high gas pressure switch, ❏ Return instructions to envelope and give to owner or place resulting in possible serious property damage due to freeze-up.

  • Page 90: Annual Startup And General Maintenance

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup and general maintenance Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see SlimFit User’s Information Manual for instructions) General: Reported problems. Check boiler area.

  • Page 91: Annual Startup

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS after the boiler is in- REMOVAL OF SIGHT GLASS GASKET stalled, perform a first-year inspection of the boiler. This must include the following The sight glass gasket in this product contains ceramic fiber materials that have...

  • Page 92: Address Reported Problems

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) 5. Check condensate fittings and condensate line to drain. Flush The boiler should be inspected and started if necessary to clean. annually, at the beginning of the heating 6.
  • Page 93 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Check expansion tank Check ignition wiring 1. Expansion tanks provide space for water to move in and 1. Check ignition cable electrical resistance. A good cable will out as the heating system water expands due to temperature have resistance between 900 and 1000 ohms.
  • Page 94 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Check burner flame (See Figure 79) Burner access The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 91 of this manual. Failure to comply could Observation result in severe personal injury.

  • Page 95: Check Boiler Relief Valve

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) When forcing a rate on a Network Priority call, only boilers running Local Priority Check flue gas temperature calls will remain on. All other boilers on the network will not fire until the Manual 1.
  • Page 96 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting Reinstall boiler jacket front door Before servicing and making connections . . . Reinstall boiler jacket front door after servicing. The boiler front door must be securely fastened to the boiler to prevent boiler from drawing air from inside the —...

  • Page 97: Checking Temperature Sensors

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Check the following: Do not jumper fuse or replace with any fuse except as specified. Failure to comply could result in severe personal injury, death or substantial property dam- 1.
  • Page 98 ® — SlimFit Series 3 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 both automatic reset conditions and manual reset to reset from them.
  • Page 99 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) 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 73.
  • Page 100 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Troubleshooting suggestions for SlimFit boilers (continued) Control Fault Displays, Diagnostics and Suggested Corrective Actions Display Condition Diagnostics Corrective Action(s) Nothing shown Control is not receiving 24V Check wiring for short circuit or Correct wiring per wiring diagram including connection of transformer on display...
  • Page 101 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) 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 Check for low water condition in system.
  • Page 102 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Troubleshooting suggestions for SlimFit boilers (continued) Display Condition Diagnostics Corrective Action(s) Occurs if manual or automatic Automatic external limit will Is there an external safety device connected? If yes, trouble shoot the LIMIT OPEN reset l imit op ens.
  • Page 103 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Troubleshooting suggestions for SlimFit boilers (continued) Display Condition Diagnostics Corrective Action(s) IGNITION Boiler went through 5 ignition Automatically resets after 1 hour Check condensate trap for blockage allowing condensate to accumulate inside heat exchanger.
  • Page 104 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 550-100-168/0516...

  • Page 105: General Maintenance

    ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Maintenance Cleaning the heat exchanger — pin Disconnect power side when required Electrical shock hazard — Disconnect all electrical 1. Shut down boiler: power to the boiler before attempting maintenance a.
  • Page 106 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Maintenance (continued) Accessing & cleaning the heat If the silicone cord gasket has been damaged or stretched, exchanger replace it before placing the boiler back in operation. To install the silicone cord gasket: Remove heat exchanger cover plate and burner...
  • Page 107 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Maintenance (continued) Removing heat exchanger cover plate Gasket Silicone cord starts and finishes at the top center Insulation Cleaning heat exchanger with cleaning tool 45° Down Horizontal 45°...
  • Page 108 FIRED WATER BOILER Replacement parts Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size and include description and part number of replacement part. Results from using modified or other manu- factured parts will not be covered by warranty and may damage boiler or impair operation.
  • Page 109 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Miscellaneous parts and kits Item Description Part Number Condensate neutralizer kit (up to 1000 MBH) 383-600-076 Heat exchanger cleaning tool 591-706-200 Pressure relief valve ASME 30 PSI, 3/4”...
  • Page 110 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Jacket parts Part Number for Item Description SlimFit 550/750 Jacket front door 383-600-052 Door seal 383-600-022 Handle (2 required) 383-500-611 Back Jacket 426-700-044 383-600-053 Jacket seal kit (base seal, door seal, grommets and gaskets) Plastic top cover (includes cover, gaskets and hardware) 383-600-054...
  • Page 111 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Jacket parts Part number 550-100-168/0516...
  • Page 112 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Heat exchanger Boiler Item Description Part Number Models 5 section heat exchanger assembly kit (includes sections, o-rings, sealing cord 383-600-029 & hardware) 6 section heat exchanger assembly kit (includes sections, o-rings, sealing cord 383-600-028 &...
  • Page 113 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Heat exchanger Part number 550-100-168/0516...
  • Page 114 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Piping Boiler Item Description Part Number Models Supply manifold kit (Includes items 5 through 8 and 10 through 14) 550 / 750 383-600-055 Return pipe kit (includes items 9 and 14) 550 / 750 383-600-035 Inlet gas pipe kit (includes items 16, 17, and 18)
  • Page 115 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Piping Part number 550-100-168/0516...
  • Page 116 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Burner, blower, venturi and gas train Part Number for Item Description SlimFit 550/750 5 section burner replacement kit (includes burner, gasket and nuts) 383-600-044 6 section burner replacement kit (includes burner, gasket and nuts) 383-600-043 Blower assembly kit (includes blower, gasket, o-ring and hardware)
  • Page 117 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Burner, blower, venturi and gas train Part number 550-100-168/0516...
  • Page 118 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Controls Part Number for Item Description SlimFit 550/750 3-amp, fast-blow ATO (5 fuses) 383-500-603 12-amp, slow-blow AG (5 fuses) 383 500 604 Control module 383-600-162 Kit - Service Conversion Series 1 to Series 2 (Includes items 3, 5, 6, 23, 24 &...
  • Page 119 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Controls Part number 550-100-168/0516...
  • Page 120 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Dimensions Dimensional data Notes Boiler supply and return connections are both 2” NPT. Circulator must be mounted in the return piping. Relief valve is shipped loose. See page 12 for mounting details. Relief valve mounts on supply pipe off of supply tee as shown. Boiler gas connection, 1¼”...
  • Page 121 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Ratings — SlimFit Series 3 boilers Ratings and engineering data AHRI Certified Ratings Boiler Gross Combustion Thermal Boiler Vent/Air Model Input Output Rating Efficiency Efficiency Water Pipe Size Number Content (inches)
  • Page 122 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Ratings — multiple SlimFit Series 3 boilers Ratings and engineering data (see Figure 106 for notes) Foundation size Total Total Total Total Manifolded Gross Boiler combustion Side-to-side Back-to-back input Output...
  • Page 123 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Ratings — multiple SlimFit Series 3 boilers (continued) Engineering data (see Figure 106 for notes) Electrical Vent/air pipe Shipping Operating Water Water flow rate service size — weight weight content...
  • Page 124 ® — SlimFit Series 3 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___ LP___ BTU Input: ____________ )ODPH VLJQDO RQ FRQWURO GLVSOD\ DW +,*+ ¿UH BBBBBBBBBBBBBBBBB )ODPH VLJQDO RQ FRQWURO GLVSOD\ DW /2: ¿UH BBBBBBBBBBBB Was venturi changed? YES___ NO___...
  • Page 125 ® — SlimFit Series 3 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 / LP input rate measured: HIGH ______ CFH / LOW________ CFH Priority 4 Settings Priority 2 Settings Priority 3 Settings...
  • Page 126 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Notes Part number 550-100-168/0516...
  • Page 127 ® — SlimFit Series 3 Boiler Manual COMMERCIAL CONDENSING GAS FIRED WATER BOILER Notes Part number 550-100-168/0516...
  • Page 128 ® — — Boiler Manual SlimFit Series 3 Boiler Manual FIRED WATER BOILER COMMERCIAL CONDENSING GAS FIRED WATER BOILER...

This manual is also suitable for:

750 mbh

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