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

Commercial condensing gas-fired water boilers
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Download this manual See also: User's Information Manual, Manual
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.
DO NOT operate the boiler during construction
free area. The boiler can be severely damaged by drywall dust or other combustion air contaminants.
Models 1000 - 2000 MBH
Commercial Condensing
Gas-fired water boilers
• Installation
• Startup
unless combustion air is piped to the boiler air inlet from a dust-free and contaminant-
Series 2
• Maintenance
• Parts
Part number 550-100-180/0917
®

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Summary of Contents for Weil-McLain 2 Series

  • 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 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER ® SlimFit Commercial Condensing Water Boiler The control can operate a single boiler or coordinate with other SlimFit Left-hand boilers (cleanout access Right-hand boilers (cleanout access on left side when facing burner end) on right side when facing burner end) 1000-2000 Series 2 boilers in a multiple boiler system.
  • Page 3 ® — Boiler Manual SlimFit Series 2 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) Cleanout panel access is on the left side when viewed from the burner end.

  • Page 4: Table Of Contents

    ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Contents Contents ....4 Hazard definitions ....4 following all instructions and procedures .
  • Page 5 See the instructions at right. contact with water, replace the boiler with a new Weil-McLain boiler. When servicing boiler — and water chemistry be checked.
  • Page 6 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler location Installations must comply with: 4. Foundation may be of wood, brick or concrete (minimum 2 inches thick) construction. Local, state, provincial, and national codes, laws, regulations and 5.
  • Page 7 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler location (continued) Openings in floors, walls, ceilings or roofs must be Clearance requirements designed for fire stopping as required by local codes. Vent pipe openings through combustible materials Clearances from combustible materials must be 3/8”...
  • Page 8 ® — Boiler Manual SlimFit Series 2 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 to ommended dimensions are not possible, 4.
  • Page 9 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler location (continued) Verify that boiler placement and clearances comply with all applicable codes. Side-by-side installation of multiple SlimFit boilers (using left-hand and right-hand boilers together) Part number 550-100-180/0917...
  • Page 10 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler Provide air openings to room 2. DIRECT EXHAUST — For direct exhaust installations, combus- tion air openings into the room must be sized to handle the SlimFit boiler and all other appliances.
  • Page 11 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler (continued) 1. See Figure 7 for the following. Cold weather handling — If boiler has been stored in a very cold location (below 32°F) before installation, 2.
  • Page 12 Weil-McLain hydrostatically pressure tests each SlimFit boiler in the factory to 1½ times maximum allowable working pressure per ASME Boiler relief valve and P/T gauge Section IV requirements.
  • Page 13 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler (continued) 3. Att ach a water supply and hand pump to the lower valves. Hydrostatic test piping connections — 4. Att ach a drain line to the upper valve. fl...
  • Page 14 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install water piping Use two wrenches when tightening water piping at boiler, Backflow preventer using one of the wrenches to prevent the boiler interior pip- 1. Use backflow check valve in cold water supply as required ing from turning.
  • Page 15 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install water piping (continued) Recommended pipe sizing Size the piping and the pumps to provide the required temperature rise. DO NOT design for flow rates above or be- See Figure 11 for boiler head loss curves.
  • Page 16 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install water piping (continued) Expansion tank and make-up water Expansion tank piping — diaphragm-type expansion tank 1. Ensure expansion tank size will handle boiler and system water volume and temperature.
  • Page 17 (1, 2 or 3). Priority 1 is defaulted to DHW for DHW Space heating to same Priority. Do not use outdoor reset for this plications. application. 3. For more than 3-zones, use Weil-McLain WMZV zone valve controller. Controlling the circulators Space Heating Connect zone valve end switches to a 1.
  • Page 18 2 or 3). Priority 1 is defaulted to DHW for DHW Priority applications. control will not run multiple priorities simultaneously. 3. For more than 3-zones, use Weil-McLain WMZV zone valve controller. Controlling the circulators Connect zone valve end switches to a Space Heating 1.
  • Page 19 1. The control can control up to four circulators (boiler circulator for DHW Priority applications. and three others). Refer to Field wiring, beginning on page 47, for 3. For more than 3-zones, use Weil-McLain WMCR zone Circ instructions on wiring to circulators. The boiler circulator cannot controller.
  • Page 20 Space Heating Priority – Space heating is priority over DHW. Use Priority applications. Priorities 1 and/or 2 for space heating; Priority 3 for DHW. The con- 3. For more than 3-zones, use Weil-McLain WMCR zone Circ trol will not run for DHW. The control will not run multiple priorities controller.
  • Page 21 DHW performance. Some local codes may require double-wall DHW heat exchanger design. Use only the an- tifreeze 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 ® — Boiler Manual SlimFit Series 2 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 installed . The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not ap- in every dwelling, building or structure used in whole or in part prove the installation unless, upon inspection, the inspector...
  • Page 23 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — general There are two venting methods available. Follow the instructions (no air piping connected to air intake) outside on the following pages for the method used. Vent and air piping materials Use only the materials listed in this manual (Figure 22, page 25) for vent and air pipe and fittings.
  • Page 24 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — general (continued) Co mbustion air contamination (combustion air from boiler room): (combustion air piped from outside): a. Provide combustion air openings to boiler room as described a.
  • Page 25 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — options 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) Canada Certified for Category IV Plastic vent pipe must be certified to...
  • Page 26 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER PVC 9HQWLQJ DOORZHG SHU UHTXLUHPHQWV VSHFL¿HG EHORZ Exhaust ONLY after 10 linear feet, WKH SLSH DQG ¿WWLQJV FDQ WKHQ EH WUDQVLWLRQHG IURP &39& WR 39& Both 5 feet lengths of pipe DQG ¿WWLQJV DUH CPVC...
  • Page 27 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — options Category II Requirements In addition to the SlimFit boilers Category IV rating gas temperature should typically be within 20°F of the return (positive pressure, likely to condense), SlimFit boilers water temperature of the boiler.
  • Page 28 Weil-McLain recommends the use of a Variable Speed Chimney Fan / Power venter to ensure that the appropri- ate 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 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — options 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: Provide a vent pipe mfr’s SlimFit VENT/AIR ADAPTER at boiler vent connection and air connection (if used).

  • Page 30: Direct Exhaust - Boiler Room Air Openings (Category Iv)

    ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Boiler room air openings Special considerations Combustion air provision The SlimFit Commercial boiler can use inside air if no contaminants Tight construction are present in the boiler space. (If contaminants are likely to be pres- National Fuel Gas Code - ANSI Z223.1/NFPA54 –...
  • Page 31 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Boiler room air openings (continued) MINIMUM combustion air openings for direct exhaust applications — Air openings SlimFit boiler SlimFit boiler The required air opening sizes below are FREE AREA, WITH other WITHOUT other after reduction for louver obstruction.

  • Page 32: Direct Exhaust - Termination Location (Category Iv)

    ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Termination location — Requirements for termination location — clearances and placement Vent Termination Locations – the minimum distance from adjacent public walkways, adjacent buildings, 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 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Sidewall Sidewall direct exhaust termination listed in Read and follow all instructions in this manual. through Locate the termination such that the total vent piping from the boiler to the termi- nation turer’s instructions.
  • Page 34 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Sidewall (continued) 2. Vent pipe penetration: Multiple boiler direct exhaust sidewall a. Cut a hole for the vent pipe. terminations (see Figure 27, page 33 for b.
  • Page 35 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Vertical Vertical direct exhaust termination listed in Read and follow all instructions in this manual. through Locate the termination such that the total vent piping from the boiler to the termi- nation turer’s instructions.
  • Page 36 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Boiler room air openings Exhaust fans and air movers Combustion/ventilation air provision For direct vent installations, combustion air must be ducted directly The appliance space must never be under a negative pressure unless from outside to the SlimFit boiler air intake fitting.
  • Page 37 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Boiler room air openings (continued) MINIMUM combustion air openings for direct vent applications — Air openings SlimFit boiler SlimFit boiler The required air opening sizes below are FREE AREA, WITH other WITHOUT other after reduction for louver obstruction.
  • Page 38 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Termination location — Requirements for termination location — clearances and placement Vent Termination Locations – the minimum distance from adjacent public walkways, adjacent buildings, 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 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Sidewall Sidewall direct vent terminations — vent and air listed in Read and follow all instructions in this manual. through and page 36 through page 38. Locate the termination such that the total vent piping from the boiler to the termi- nation...
  • Page 40 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Sidewall (continued) 3. Vent pipe penetration: Multiple terminations — clearance from a. Cut a hole for the vent pipe. vent of one to air intake of the next b.
  • Page 41 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Vertical Vertical direct vent terminations (air termination can be vertical or sidewall as shown below). Read and follow all instructions in this manual. through and page 36 through page 38 Locate the termination such that the total vent piping from the boiler to the termination...
  • Page 42 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Vertical (continued) Install vent and air terminations 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 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Vertical (continued) Termination location — multiple boilers — vertical vent/sidewall air. — Space vents minimum 6 inches apart. Space air terminations minimum 6 inches apart.
  • Page 44 Condensate from the SlimFit boiler will be slightly acidic (typically with a pH from 3.2 to 4.5). Install a neutralizing fi lter if required by local codes. See Replacement parts sec- tion at the end of this manual for a Weil-McLain condensate neutralizer kit. Condensate pump capacity, GPH...

  • Page 45: Gas Piping

    ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Gas piping . Th e boiler is suitable for fi ring ONLY natural gas. Failure to comply could result in severe personal injury, death or gas piping at boiler , using one wrench to substantial property damage.
  • Page 46 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Gas piping (continued) Pipe sizing 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 pipe 2.
  • Page 47 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see Wiring must be N.E.C. Class 1. If original wiring For your HAZARD — as supplied with boiler must be replaced, use safety, turn off electrical power supply at service only type 105 °C wire or equivalent.
  • Page 48 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) Schematic wiring diagram — SlimFit boilers (continued on next page) Part number 550-100-180/0917...
  • Page 49 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) (continued from previous page) Schematic wiring diagram — SlimFit boilers Part number 550-100-180/0917...
  • Page 50 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) Ladder wiring diagram — SlimFit boilers (continued on next page) Part number 550-100-180/0917...
  • Page 51 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (continued) (continued from previous page) Ladder wiring diagram — SlimFit boilers Part number 550-100-180/0917...
  • Page 52 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see (continued) A. 120 VAC Power Supply – REQUIRED 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 Primary / secondary piping is recommended to be used with the 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 –...
  • Page 54 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see (continued) – REQUIRED 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 sensors will provide SlimFit faster response.
  • Page 55 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see (continued) G. External limits – OPTIONAL To cause MANUAL 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 lockout if the limit circuit opens.
  • Page 56 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see (continued) I. Closure switch (flow switch and/or CAD) – OPTIONAL 1. A flow switch or combustion air damper (CAD) interlock can be configured by removing jumper.
  • Page 57 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see (continued) J. 0 –10 VDC Remote TARGET input – OPTIONAL 1. See illustration at right and Figure 52, page 48 (wiring diagram) for details. 2. Remote target using 0–10VDC input requires a 0–10VDC input signal at P15-4/5 as shown at right.
  • Page 58 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see (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 59 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see (continued) L. 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 (8) boilers in one installation.
  • Page 60 ® — Boiler Manual SlimFit Series 2 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 outputs) and page 53 (24VAC inputs). 2.
  • Page 61 ® — Boiler Manual SlimFit Series 2 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 out- puts) and page 53 (24VAC inputs).
  • Page 62 ® — Boiler Manual SlimFit Series 2 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 Fig- Control action status ure 61, page 68 and following pages for information.)
  • Page 63 ® — Boiler Manual SlimFit Series 2 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 maximum Step 1 and minimum times a system will be operated before being turned...
  • Page 64 ® — Boiler Manual SlimFit Series 2 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 65 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup (continued) SlimFit single boiler essential settings ( on initial start-up) — see page 67 for explanation Part number 550-100-180/0917...
  • Page 66 ® — Boiler Manual SlimFit Series 2 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 550-100-180/0917...
  • Page 67 ® — Boiler Manual SlimFit Series 2 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 68 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER CONTRACTOR menus 1. Access contractor menus by pressing and holding the UP and cal settings. Failure to set correctly could result in DOWN arrow keys at the same time for 7 seconds. severe personal injury, death or substantial property damage.
  • Page 69 ® — Boiler Manual SlimFit Series 2 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. cal settings. Failure to set correctly could result in severe personal injury, death or substantial property 2.
  • Page 70 ® — Boiler Manual SlimFit Series 2 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. cal settings.
  • Page 71 ® — Boiler Manual SlimFit Series 2 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. cal settings. Failure to set correctly could result in severe personal injury, death or substantial property 2.
  • Page 72 ® — Boiler Manual SlimFit Series 2 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 71) Option Hot loop for seasonal boilers that are manually Output is always energized whenever the control is powered.
  • Page 73 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTIC menu menu navigation (see Figure 58, page 66 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 74 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) Figure 68, page 74 menu navigation, continued (see Figure 68, page 74 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 75 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) menu details (see Figure 58, page 66 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 76 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) menu details (continued) (see Figure 58, page 66 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 77 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) menu details (continued) (see Figure 58, page 66 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 78 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER MAINTENANCE, DATE AND TIME menus menus — navigation (see Figure 58, page 66 for access information) Name Contractor name to appear in maintenance reminders and during lockouts Phone Contractor phone number Model...
  • Page 79 1. If necessary, use an approved chemical cleaning agent, following McLain.com. the manufacturer’s guidelines for procedures. 2. See Replacement parts at the end of this manual for Weil-McLain a. A list of approved cleaning products is available at www. part numbers to obtain antifreeze through a Weil-McLain dis- Weil-McLain.com.
  • Page 80 Weil-McLain provides information for application of inhibitor as needed to bring to acceptable level, using inhibitor the antifreeze products listed in this document only for use in Weil-McLain SlimFit boilers. Do not apply test kit to verify. these products or instructions for other applications.
  • Page 81 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Startup — fi nal checks Check thermostat circuit(s) Pressure switches 1. Disconnect the two external wires connected to the boiler Y-fi tting with WHITE thermostat terminals (see instructions beginning on page 47 for hoses to top of switches terminal locations).
  • Page 82 “Check flame & combustion For elevations above 10,000 feet, please contact with instruments, page 82. ” Weil-McLain Technical Support for details. 2. Boiler behavior that might indicate a need to check combustion In Canada, Input rates are derated 10% for altitudes of values at high fire (as per page 82) to verify boiler is in adjustment...
  • Page 83 Figure 75 , follow when completed. the procedure given for adjusting the thrott le 6. Consult your local Weil-McLain representative if acceptable results cannot screw on the gas valve. If thrott le screw ad- be obtained for both high and low fi re.
  • Page 84 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Startup procedure (continued) ❏ For multiple zones, adjusted for correct flow in each zone? 6. After gas valve 1 has opened, end the call for heat. ❏ Verified thermostat heat anticipator (if available) set properly 7.
  • Page 85 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Startup procedure (continued) Operating instructions (WARNING — Verify that the control is set correctly before proceeding Part number 550-100-180/0917...
  • Page 86 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup and maintenance schedule 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. Check boiler area.

  • Page 87: Annual Startup

    ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS after the boiler is installed, REMOVAL OF SIGHT GLASS GASKET perform a first-year inspection of the boiler. This must include the following in addition to routine annual The sight glass gasket in this product contains...
  • Page 88 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Air inlet box screen The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Figure 79, page 86 and explained on the following pages must be per-...
  • Page 89 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Following installation, the valve lever must be operated Flue vent system and combustion air AT LEAST ONCE A YEAR to ensure that waterways piping are clear.
  • Page 90 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Inspect ignition electrode Gas valve and venturi 1. Remove the ignition electrode from the boiler heat ex- changer burner end section. See image at right. Ignition Plastic reference tube electrode is longer than the fl ame sensor (see below) and has a brown ceramic insulator.
  • Page 91 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Perform startup procedure per manual Combustion chamber access cover removal 1. Perform all startup procedures on pages page 82 through page 85. Check burner flame 1. Inspect flame through the observation window using the proce- dure on page 82.
  • Page 92 ® SlimFit Series 2 commercial condensing gas-fired water boiler — Boiler Manual Annual startup (continued) c. Insert burner into machined pocket on end section, burner 4. If flame signal still remains low, inspect the vent and air piping. Then should tilt down slightly as the end of the burner rests on inspect the heat exchanger, following the procedures given in this opposite end section.

  • Page 93: Troubleshooting

    ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting Before servicing and making connections . . . — The boiler ON/OFF switch does not turn off all power to the boiler. . Internal wiring is still powered when the switch is off .
  • Page 94 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Check the following: 5. Reinstall jacket top panel and boiler jacket door after checking 1. Space heating: the fuses. a. Make sure thermostat is calling for heat and contacts (includ- 6.
  • Page 95 ® — Boiler Manual SlimFit Series 2 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 both 2.
  • Page 96 ® — Boiler Manual SlimFit Series 2 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 SET- 1. Selecting this will prompt the user to hold the enter button for TINGS menu, see Figure 62, page 69.
  • Page 97 ® — Boiler Manual SlimFit Series 2 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 98 ® — Boiler Manual SlimFit Series 2 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 99 ® — Boiler Manual SlimFit Series 2 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 100 ® — Boiler Manual SlimFit Series 2 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 101 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 550-100-180/0917...
  • Page 102 Inspect cleanout plate gasket leading to reduced heat exchanger life. 1. Inspect the cleanout plate gasket (Figure 93, page 103). Replace 4. Weil-McLain recommends Sentinel X400 for cleaning boiler. See if damaged. the Repair Parts section at the end of this manual for ordering information.
  • Page 103 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Maintenance (continued) Cleanout plate removal/re-installation Using the cleaning tool Silicone cord must start/end at top center, add a dap of silicone over joint. 45° Down Cleanout plate Horizontal Cleanout plate gasket Silicone cord gasket...
  • Page 104 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Maintenance (continued) Cleanout plate nut tightening sequences the cleanout plate nuts in the sequence shown in Figure 95 until torque reaches 18 N-m/160 in-lbs/13 ft-lbs. If the tightening is not done using this top-to-bottom, center out method, the plate could buckle, allowing a flue gas leakage.
  • Page 105 Series 2 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 a lo- Weil-McLain part numbers are found in Weil-McLain cal Weil-McLain distributor. When ordering, specify Boilers and Controls Repair Parts Lists.
  • Page 106 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors Jacket parts Item Description Part Number 426-700-330 Jacket side post with mounting plate 383-600-249 Support frame bracket kit (Frame components, hardware)
  • Page 107 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Jacket parts Part number 550-100-180/0917...
  • Page 108 — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors 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 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Heat exchanger Part number 550-100-180/0917...
  • Page 110 Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors 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 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Burner, blower, venturi and gas train Part number 550-100-180/0917...
  • Page 112 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors Controls Item Description Part Number Display panel assembly kit 383-600-501 Ignitor kit (ignitor, gasket, hardware, ground harness)
  • Page 113 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Controls Part number 550-100-180/0917...
  • Page 114 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Dimensions 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 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Dimensions (continued) 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 116 ® — Boiler Manual SlimFit Series 2 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Ratings — SlimFit Series 2 boilers Ratings and engineering data AHRI Ratings Boiler Boiler Gross Combustion Thermal Water Vent/Air Stack/vent Boiler weight Model Output Input Rating Efficiency Efficiency Content Pipe Size...
  • Page 117 ® — Boiler Manual SlimFit Series 2 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. ❏...
  • Page 118 ® — Boiler Manual SlimFit Series 2 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: ____________ )ODPH VLJQDO RQ FRQWURO GLVSOD\ DW +,*+ ¿UH BBBBBBBBBBBBBBBBB )ODPH VLJQDO RQ FRQWURO GLVSOD\ DW /2: ¿UH BBBBBBBBBBBB Was venturi changed? YES___ NO___...
  • Page 119 ® — Boiler Manual SlimFit Series 2 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 ® — Boiler Manual — Boiler Manual ™ SlimFit SlimFit Series 2 COMMERCIAL CONDENSING GAS COMMERCIAL CONDENSING GAS FIRED WATER BOILER FIRED WATER BOILER...

This manual is also suitable for:

Slimfit sf1500lSlimfit sf1000lSlimfit seriesSlimfit sf2000lSlimfit sf1000rSlimfit sf1500r ... Show all