Weil-McLain 2 Series Manual page 92

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SlimFit Series 2 commercial condensing gas-fired water boiler — Boiler Manual
Annual startup
c. Insert burner into machined pocket on end section, burner
should tilt down slightly as the end of the burner rests on
opposite end section.
d. Place Burner gasket over studs and against burner.
15. Carefully slide blower/venturi/mixing adapter onto the M12
studs.
The blower/venturi/mixing adapter assembly is
heavy, weighing up to 60 pounds on larger units.
Handle carefully to avoid possible personal injury
or damage to the components.
16. Make sure that the burner flange is still resting inside the ma-
chined pocket on the end section.
17. Tighten the M12 flange nuts on the Mixing adapter to 22 Ft-
lbs (30 N-m).
18. Connect gas manifold back to gas valve with the M5 Allen
bolts (4), with torque 53 in-lbs (6 N- m).
is still in position on the gas valve.
19. Reconnect air inlet pipe to venturi, with torque 53 in-lbs
(6 N- m).
20. Reconnect plastic reference line to venturi push tube into
fitting. The fitting will self-tighten on the tube. Test the con-
nection by lightly pulling on the plastic tube.
21. Press the air flow switch tube back onto the venturi hose barb.
The air flow switch hose and plastic reference line
MUST be replaced correctly on the venturi.
22. Reconnect the two (2) blower wire harnesses.
23. Re-install the piping end section combustion chamber access
plate assembly. Tighten the M12 flange nuts on the access plate
22 Ft-lbs (30 N-m).
24. Re-install the igniter assembly and flame sensor assembly. Make
sure the gaskets are in good condition.
25. Re-attach the wiring connections to the igniter and flame
sensor.
26. Verify there are no gas/air leaks.
27. Reconnect any wiring that was disconnected.
28. Retest the boiler, making sure the flame is acceptable after
the cleaning.
Check flame signal
1. Navigate to Diagnostics/Inputs on the Control display (see
Figure 67, page 73).
2. If the flame signal drops to less than 24 above the Shutdown
values, the Control will attempt to correct by increasing the
boiler firing rate to increase flame signal.
3. A lower flame signal may indicate a fouled ignitor or damaged
ignitor insulation. If cleaning the ignitor does not improve,
ground wiring is in good condition, and ground continuity is
satisfactory, replace the ignitor.
Figure 86
Flame signal shutdown values
Model
SlimFit – flame signal
1000
1500
2000
92
(continued)
Make sure O-ring
Boost Shutdown
flame signal
40 16
40 16
40 16
4. If flame signal still remains low, inspect the vent and air piping. Then
inspect the heat exchanger, following the procedures given in this
manual for removal and reinstallation of the heat exchanger cover plate
and other boiler components. Clean the heat exchanger as described
in this manual if necessary.
Check flue gas temperature
1. Set the boiler to high fire. Then adjust the control module display to
view flue gas temperature and boiler return temperature.
2. The flue gas temperature should be no more than 30°F higher than
the boiler return temperature.
3. If the flue temperature is higher than this, shut down the boiler, allow
to cool, and follow the procedure starting on page 102 to clean the
heat exchanger.
Check blower speeds
1. For installations at altitudes above 5,500 feet, make sure the control is
set up for high altitude in the boiler setup menu. The Control module
automatically adjusts low fire and ignition rates to compensate for
high altitude conditions.
2. For installations below 5,500 feet, DO NOT enable high altitude.
3. Use the Control display to navigate to Manual test mode (see
Figure 68, page 74).
4. Set the firing rate to Low (low fire).
5. Write down the blower RPM value shown and compare to the value
in the table in Figure 74, page 82. Low fire rate (and corresponding
blower speed) is adjusted in the boiler setup menu.
6. Set the firing rate to MEDIUM (ignition rate).
7. Write down the blower RPM value. It should be within 200 RPM of
the value listed in the table in Figure 74, page 82.
8. Set the firing rate to High (high fire).
9. Write down the blower RPM value. It should be within 200 RPM of
the value given in the table in Figure 74, page 82.
10. If any of the values are outside the ranges listed in the previous steps,
contact the factory for technical assistance.
Manual Test Mode for Single and
Multiple Boilers
Single Boiler
1. Navigate to Manual Test Mode screen under DIAGNOSTICS menu.
2. Generate a call for heat and wait until the burner is lit, if not yet in
operation.
3. Press ENTER and select the desired FORCE RATE. Rate will be
forced to setting for 10 minutes.
Review with owner
1. Review the SlimFit User's Information Manual with the owner.
2. Emphasize the following to the owner:
a. Perform the maintenance schedule specified in the User's Infor-
mation Manual.
b. Call a licensed contractor should the boiler or system exhibit any
unusual behavior.
c. Follow the proper shutdown procedure.
d. Schedule an annual startup at the beginning of the next heating
season.
Part number 550-100-180/0917