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Weil-McLain SlimFit Manual

Commercial condensing gas-fired water boilers
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Boiler Manual
This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this
manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to
comply could result in severe personal injury, death or substantial property damage.
DO NOT operate the boiler during construction
and contaminant-free area. The boiler can be severely damaged by drywall dust or other combustion air contaminants.
Commercial Condensing
Gas-fired water boilers
• Installation
• Maintenance
• Startup
• Parts
unless combustion air is piped to the boiler air inlet from a dust-free
Part number 550-100-116/0713
TM

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Summary of Contents for Weil-McLain SlimFit

  • Page 1 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. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
  • Page 2 Vent pipe connection, 10-inch nominal (9.85” I.D.). Installer must provide a vent/ The automatic gas valve incorporates two solenoid-operated valve seats. The air pipe manufacturer’s SlimFit Vent/Air Adapter to adapt to the vent pipe used. valve senses the vacuum in the venturi (item 5) caused by flowing air. Gas flows...
  • Page 3 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler SlimFit ™ Commercial Condensing Water Boiler (Model SF1000 shown) Configuration options Electrical panel components (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

    Install condensate components Replacement parts Gas piping Dimensions Field wiring (see Figure 56 & Figure 57) Ratings — SlimFit boilers Sola control overview & sequence of operation Sola control interface and menus Installation and Service Certificate 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.

  • Page 5: Please Read Before Proceeding

    Weil-McLain boiler. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage When servicing boiler —...

  • Page 6: Prepare Boiler Location

    33 x 75 substantial property damage. SF1500 33 x 75 3. The SlimFit boiler must be installed so that gas control system SF2000 33 x 87 components are protected from dripping or spraying water or rain during operation or service.

  • Page 7: Clearance Requirements

    SlimFit — 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 materials Clearances from combustible materials must be 3/8”...
  • Page 8 Figure 4 or Figure 6. boilers for access and servicing. If rec- boiler pump and other accessories. Figure 4 Side-to-side mounting of multiple SlimFit boilers — LEFT-HAND boilers only Figure 5 Side-to-side mounting of multiple SlimFit boilers — RIGHT-HAND boilers only Part number 550-100-116/0713...
  • Page 9 — Boiler Manual ™ commercial condensing gas fired water boiler Prepare boiler location (continued) Verify that boiler placement and clearances 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 550-100-116/0713...

  • Page 10: 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. See the direct exhaust venting Air openings — General instructions in this manual for required openings.
  • Page 11 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Prepare boiler (continued) 1. See Figure 8 for the following. Cold weather handling — If boiler has been stored 2. Move the crate to a solid, level surface. in a very cold location (below 32°F) before installation,...

  • Page 12: Placing The Boiler

    . This is the maximum allowable relief valve 1½ times the pressure setting of the relief valve setting for the SlimFit boiler. The boiler is shipped with a to be installed on the unit (45 psig for a 30-psig 30 PSIG relief valve. See Replacement parts in the back of relief valve;...
  • Page 13 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Prepare boiler (continued) 3. Attach a water supply and hand pump to the lower valves. Figure 10 Hydrostatic test piping connections — 4. Attach a drain line to the upper valve.

  • Page 14: Install Water Piping

    This is the maximum allowable relief valve exchanger. Some codes/jurisdictions may require additional setting for the SlimFit boiler. The boiler is external controls. shipped with a 30 PSIG relief valve. See Re-...
  • Page 15 Figure 13, use ONLY primary/second- Temperature Rise (°F) Boiler head loss (Feet w.c.) ary piping. Size the boiler pump for the proper flow rate. 44.5 38.3 Figure 11 Boiler head loss vs flow rate for SlimFit boilers ** 63 30.4 27.4 24.0 10.9 21.3 13.3...
  • Page 16 SlimFit — 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 2. Connect DHW (domestic hot water) piping to indirect storage water heater as shown. Connect from the DHW tank aquastat to the DHW terminals on the SlimFit boiler. DHW tanks piped using this arrangement need to be sized for the required load, with a DHW pump selected to provide a flow rate through the boiler and tank that is within the allowable flow rate range listed in Figure 13, page 15 of this...
  • Page 18 3. Connect DHW (domestic hot water) piping to indirect storage water heater as shown. Connect from the DHW tank aquastat to the DHW terminals on the SlimFit boiler. DHW priority — Set the Sola control for the desired DHW priority mode.
  • Page 19 4. Connect DHW (domestic hot water) piping to indirect storage water heater as shown. Connect from the DHW tank aquastat to the DHW terminals on the SlimFit boiler. DHW tanks piped using this arrangement need to be sized for the required load, with a DHW pump selected to provide a flow rate through the boiler and tank that is within the al- lowable flow rate range listed in Figure 13, page 15 of this...
  • Page 20 Typical radiant heating system piping plus optional DHW 1. The SlimFit boiler is ideal for use in radiant heating. The SlimFit boiler’s unique heat exchanger design allows it to work well even in condensing mode. So there is no need to regulate boiler return water temperature in radiant heating applications.
  • Page 21 3. Connect DHW (domestic hot water) piping to indirect storage water heater as shown. Connect from the DHW tank aquastat to the DHW terminals on the SlimFit boiler. DHW tanks piped using this arrangement need to be sized for the required load, with a DHW pump selected to provide a flow rate through the boiler and tank that is within the allow- able flow rate range listed in Figure 13, page 15 of this manual.

  • Page 22: Multiple Boiler Water Piping

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Multiple boiler water piping Multiple boiler piping System design and sizing information in this 1. Primary/secondary piping manual are intended as suggested guidelines a. Use only primary/secondary piping, as shown on the following only.
  • Page 23 Multiple boiler water piping (continued) Figure 21 Piping schematic — typical piping for multiple SlimFit boilers, using multiple boiler manifolds Legend — Figure 21 1 Flow/check valve (each boiler) 11 Check valve or backflow preventer, as required by applicable codes...
  • Page 24 Multiple boiler water piping (continued) Figure 22 Piping layout — typical piping for multiple SlimFit boilers, using multiple boiler manifolds • Use 3” or larger piping for all • Follow all sizing guidelines on • Use recognized engineering connections between boilers and page 15.
  • Page 25 Multiple boiler water piping (continued) Figure 23 Piping layout — typical piping for multiple SlimFit boilers, with multiple DHW storage heaters connected as a secondary circuit • Use 3” or larger piping for all • Follow all sizing guidelines on •...
  • Page 26 Multiple boiler water piping (continued) Figure 24 Piping layout — typical piping for multiple SlimFit boilers, with DHW storage heater (or heaters) direct-piped to one of the boilers DHW tanks piped using this arrangement need to be sized for the required load, with a DHW pump selected to provide a flow rate through the boiler and tank that is within the allowable flow rate range listed in Figure 13, page 15 of this manual.
  • Page 27 Multiple boiler water piping (continued) Figure 25 Piping layout — typical piping for multiple SlimFit boilers, using isolation exchanger Use an isolation heat exchanger for: • Large volume systems with high mineral content in water.

  • Page 28: Venting/Combustion Air - General

    2. Combustion air can be piped individually for each boiler, or it can be manifolded as shown in Figure 35, page 40. Combustion/ 2. Where the SlimFit boiler shares a space with other appliances, ventilation openings may also be required in boiler room walls, the combustion air openings must be sized to handle the com- bined requirements of all appliances in the space.

  • Page 29: Combustion Air Contamination

    (combustion air from boiler room): (combustion air piped from outside): a. Provide combustion air openings to boiler room as described a. Install air inlet piping for the SlimFit boiler as described in in this manual. this manual. b. Ensure the boiler room and combustion air source areas are b.

  • Page 30: Venting/Combustion Air - Options

    USE ONLY the pipe materials listed in Figure 28, page 31 | See Figure 107, page 115 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). See Fig- ure 107, page 115 for part/kit numbers Provide vent pipe manufacturer’s reducer(s) as needed to meet vent/air pipe size used.
  • Page 31 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Venting/combustion air — options (continued) Figure 28 Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet local codes (see Figure 107, page 115 for vent/air part/kit numbers)

  • Page 32: Appliances Remaining On An Existing Vent System

    SlimFit boiler, the SlimFit boiler CANNOT use the existing com- main burner operation. Use the flame of a match or candle, or mon vent. The SlimFit boiler requires its own vent and air piping, as smoke from a cigarette, cigar, or pipe.

  • Page 33: Venting/Air Piping - Massachusetts Installations

    SlimFit — 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 installed INSPECTION . The state or local gas inspector of the side...

  • Page 34: Direct Exhaust - Boiler Room Air Openings

    Special considerations Combustion air provision Tight construction The SlimFit Commercial boiler can use inside air if no contaminants are present in the boiler space. (If contaminants are likely to be pres- ANSI Z223.1 defines unusually tight construction where: ent, install the boiler as a direct vent appliance, using the appropriate 1.

  • Page 35: Air Openings

    DIRECT EXHAUST — Boiler room air openings (continued) Figure 29 MINIMUM combustion air openings for direct exhaust applications — ALL OPENING SIZES ARE FREE AREA Air openings SlimFit boiler SlimFit boiler WITH other WITHOUT other The required air opening sizes below are FREE AREA, after reduction for louver obstruction.

  • Page 36: Direct Exhaust - Termination Location

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler DIRECT EXHAUST — Termination location Figure 30 DIRECT EXHAUST INSTALLATIONS — Requirements for termination location — clearances and placement Part number 550-100-116/0713...

  • Page 37: Direct Exhaust - Sidewall

    1. Install the vent manufacturer’s SlimFit Vent Adapter in the boiler Multiple vent terminations vent outlet. Follow all vent manufacturer instructions. 1. When terminating multiple SlimFit boilers, terminate each vent 2.
  • Page 38 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler DIRECT EXHAUST — Sidewall (continued) 2. Vent pipe penetration: Figure 32 Multiple boiler direct exhaust sidewall a. Cut a hole for the vent pipe. terminations (see Figure 31, page 37 for b.

  • Page 39: Direct Exhaust - Vertical

    Follow vent/air for fittings. pipe manufacturer’s instructions for proper protection 1. Install the vent manufacturer’s SlimFit Vent Adapter in the boiler and support of the piping and for installations in very vent outlet. Follow all vent manufacturer instructions.

  • Page 40: Direct Vent - Boiler Room Air Openings

    SlimFit boiler, the boiler room will still require air open- pliances, but also to handle the air movement rate of the exhaust fans ings, either for ventilation or for combustion air for other appliances or air movers using air from the building or space.
  • Page 41 If the space is smaller, provide ONE opening to a larger room with at least 3,000 square inch per Btuh of SlimFit boiler input. openings are required if the openings, each at least: boiler installation provides at least the square inch per...

  • Page 42: Direct Vent - Termination Location

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler DIRECT VENT — Termination location Figure 37 DIRECT VENT INSTALLATIONS — Requirements for termination location — clearances and placement Part number 550-100-116/0713...

  • Page 43: Direct Vent - Sidewall

    Do not exceed the maximum lengths of the outside vent 1. Install the vent manufacturer’s SlimFit Vent Adapter in the boiler piping shown in Figure 38. Excessive length exposed vent outlet. Follow all vent manufacturer instructions.
  • Page 44 Direct venting — install tee on air outlet or provide means to disassemble the air piping to allow access to the inlet air filter Vent/air pipe manufacturer’s SlimFit Vent/Air Adapter, 8-inch outlet Vent/air pipe manufacturer’s tee, 8-inch — orient the tee...

  • Page 45: Direct Vent - Vertical

    1. Install the vent/air pipe manufacturer’s SlimFit Vent Adapter in Follow vent/air pipe manufacturer’s instructions for proper protection and support of the piping and for the boiler vent and air outlets.
  • Page 46 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler DIRECT VENT — Vertical (continued) Install vent and air terminations Figure 43 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 47 Vent/air pipe manufacturer’s SlimFit Vent/Air Adapter, 8-inch outlet Vent/air pipe manufacturer’s tee, 8-inch — orient the tee so the cover will be on the...

  • Page 48: 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 sec- tion at the end of this manual for a Weil-McLain condensate neutralizer kit. Figure 50...

  • Page 49: Gas Piping

    Gas piping DO NOT connect the SlimFit boiler to a propane sup- Use two wrenches when tightening . The boiler is suitable for firing ONLY natural gas. Failure to comply could result in severe personal injury, death or...

  • Page 50: Pipe Sizing

    Equivalent length, feet Gas pressure switches Pipe size inches 90° Elbow 1. SlimFit boilers are equipped with manual reset high gas pressure and low gas pressure switches (see Figure 52, page 49). 1½ 4.02 8.04 2.

  • Page 51: Field Wiring (See Figure 56 & Figure 57)

    1. All field wiring connects to the labeled terminal strips on top of the Figure 55 Line voltage and pump connections SlimFit boiler. See page 3 for location. The terminal strip sections are (terminal strips A and D) labeled A, B, C, D, E and F.
  • Page 52 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Field wiring (see Figure 56 & Figure 57) (continued) Figure 56 Schematic wiring diagram — SlimFit boilers (continued on next page) Part number 550-100-116/0713...
  • Page 53 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Field wiring (see Figure 56 & Figure 57) (continued) Figure 56 (continued from previous page) Schematic wiring diagram — SlimFit boilers Part number 550-100-116/0713...
  • Page 54 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Field wiring (see Figure 56 & Figure 57) (continued) Figure 57 Ladder wiring diagram — SlimFit boilers (continued on next page) Part number 550-100-116/0713...
  • Page 55 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Field wiring (see Figure 56 & Figure 57) (continued) Figure 57 (continued from previous page) Ladder wiring diagram — SlimFit boilers Part number 550-100-116/0713...

  • Page 56: Outdoor Temperature Sensor

    Low water cutoff (Factory wired in boiler) heating systems supplied by the boiler). 1. SlimFit Commercial boilers are equipped with a manual reset low water cutoff, with its probe in the upper right of the burner end Factory default pump assignments section.
  • Page 57 IEEE RS-485. 2. Connect a dry contact across terminal strip B “TIME OF DAY” 4. If the BMS uses BACnet protocol, install a BACnet converter terminals to use this function. between the BMS and the SlimFit BMS input terminals. Part number 550-100-116/0713...

  • Page 58: Sola Control Overview & Sequence Of Operation

    Some of the Sola features: 1. Heat request detected (On Setpoint – On Hysteresis). ❏ Blower speed modulation to control the SlimFit boiler’s firing rate. 2. The space heating pump(s) is switched on. ❏ Advanced PID response to anticipate system needs based on response to heat input.

  • Page 59: Outdoor Reset Operation

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control overview & sequence of operation (cont.) 10. At the end of the CH-heat request the burner is Outdoor reset operation switched off and the blower stays on until post purge 1.

  • Page 60: Sola Control Interface And Menus

    — Lockout condition YELLOW 2. The stand-by screen (screen saver showing WEIL-McLAIN — Holding mode (this is a normal conditions, and indicates that the control is wait- logo) appears if the display is left idle for a time and screen saver...

  • Page 61: Sola Control Interface And Menus

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control interface and menus (continued) Figure 62 Sola display page flow — top row below shows buttons available from the home page (must log in to change) Most pages have a Home button...

  • Page 62: Sola Control Interface And Menus

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control interface and menus (continued) Configuration 3. The lockout history can be displayed by accessing the History screens as described in the next section. (HOME PAGE CONFIGURE) 1. Most parameter setup changes are done with one of the CON- History and Alert Log FIGURATION GROUPS shown in Figure 62, page 61.

  • Page 63: Sola Control Interface And Menus

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control interface and menus (continued) Figure 66 Figure 68 History screen, typical Alert log example 4. History screen overview a. The entire 15 fault code history is displayed in a scrollable list, Diagnostics Button with faults listed in reverse order of occurrence.

  • Page 64: Sola Control Interface And Menus

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control interface and menus (continued) Figure 70 Figure 72 Analog I/O Status page Pump test. Diagnostics Tests Trend Analysis (HOME PAGE DETAILS ANALYSIS) (HOME PAGE DIAGNOSTICS DIAGNOSTICS TESTS) 1.

  • Page 65: Sola Control Interface And Menus

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control interface and menus (continued) 3. Trend analysis graph page Press the SAVE button to store a snapshot of the screen. While this snapshot is saved, trend data sampling is a.

  • Page 66: Sola Control Interface And Menus

    WAY? is NOT checked unless the boiler is connected to a BMS. marked as “Unknown” when no configuration information If a BMS is used, see the SlimFit Modbus manual for details. exists. Normally, control configuration data collection only 7. Press the Screen Saver tab to select the screen saver and to set needs to be performed when the control is initially installed.

  • Page 67: Sola Control Interface And Menus

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control interface and menus (continued) Figure 79 Figure 81 Display diagnostics Processor Reset 8. Each test is invoked by pressing the TEST button next to the 2. When the Display is reset, the display will reboot and automati- diagnostic.

  • Page 68: Personal Injury, Death Or Substantial Property

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control express setup — single boiler Figure 83 Factory default settings (most common Sola control single boiler setup parameters— see complete list in “Sola control parameter table” beginning on page 72 1.

  • Page 69: Zoning With Zone Valves

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control express setup — single boiler (continued) Zoning with zone valves — Analog input option — setpoint Primary/secondary piping 1. Go to HOME PAGE CONFIGURE CH–CEN- [Apply for Figure 16, page 17 or Figure 17, page 18] TRAL HEAT CONFIGURATION 1.

  • Page 70: Sola Control Express Setup - Multiple Boilers

    Multiple boiler system requirements common parameters — see complete list in “Sola control parameter table” beginning on page 72 Up to 8 SlimFit boilers on a system. • • Boilers must be connected from boiler to boiler with twisted Temperatures —...
  • Page 71 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control express setup — multiple boilers (continued) MASTER boiler setup SLAVE boiler setup 1. System sensor — attach the system sensor to the system supply pip- Enable slave boiler ing.

  • Page 72: Sola Control Parameter Table

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table HOME PAGE CONFIGURATION Figure 85 Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus (...
  • Page 73 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 74 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 75 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 76 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 77 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 78 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 79 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 80 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 81 Varies by boiler model Ignition. Burner Control Ignition (read only — not changeable) Pilot test hold Not changeable Does not apply to SlimFit boiler Flame threshold Not changeable Burner Control Flame Failure (read only — not changeable) Retry N If ignition fails then several responses are possible. This parameter Ignite failure selects one of these responses.
  • Page 82 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 83 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 84 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 85 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...
  • Page 86 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola control parameter table (continued) HOME PAGE CONFIGURATION Figure 85 (continued) Sola CONFIGURATION VALUES — setup options — White text on black titles are configuration groups — see Figure 62, page 61 for location of configuration group in menus...

  • Page 87: Startup - Fill The System

    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 88: Personal Injury, Death Or Substantial Property

    Or use the Sentinel inhibitor test kit to check concentration. 2. If pH is outside this range (or inhibitor test kit indicates low level), 1. The SlimFit boiler must have Sentinel X100 added to the system the inhibitor level may not be sufficient to prevent corrosion.

  • Page 89: Startup - Final Checks

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Startup — final checks Check thermostat circuit(s) Figure 86 Pressure switches 1. Disconnect the two external wires connected to the boiler Y-fitting with WHITE thermostat terminals (see instructions beginning on page 51 for hoses to top of switches terminal locations).

  • Page 90: Startup Procedure

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Startup procedure 3. If the rate on the display is correct, proceed to start. 4. If the rate must be changed, press the Lightoff rate line. Figure 87 To manually set firing rate for testing: a.

  • Page 91: Gas Valve Adjustment Procedure

    Solenoid indicator fire setting. The process may need to be repeated. lights (V1 & V2) 4. Consult your local Weil-McLain representative if acceptable results cannot be obtained for both high and low fire. Part number 550-100-116/0713...
  • Page 92 Reconnect gas ❏ Filled in Installation certificate on page 128? valve electrical harness. ❏ Filled out the warranty registration card and send to Weil-McLain? 11. Turn power back on to boiler. Return instructions to envelope and give to owner or place 12.
  • Page 93 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Startup procedure (continued) Figure 91 Operating instructions (WARNING — Verify that the Sola is set correctly before proceeding Part number 550-100-116/0713...

  • Page 94: Sola Information And Operations Screens

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola Information and Operations screens DO NOT OPERATE THIS Startup — fill the system (page 87) Failure to follow the instructions in BOILER without follow- this manual could result in severe Startup —...
  • Page 95 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Sola Information and Operations screens (continued) Figure 92 Sola display information and operation screen navigation Make sure to return the boiler to automatic opera- tion after using the operation screen for manual op- Press the boiler icon eration.

  • Page 96: Annual Startup And Maintenance Schedule

    Figure 93 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. Inspect air inlet box screen; clean and vacuum if necessary; WARNING — no •...

  • Page 97: Annual Startup

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Annual startup HAnDLInG CERAMIC FIBER FIRST-YEAR SPECIAL InSPECTIOn MATERIALS No later than 12 months after the boiler is installed, REMOVAL OF SIGHT GLASS GASKET obtain an Annual Maintenance kit and perform a first-year inspection of the boiler.

  • Page 98: Address Reported Problems

    10. Tighten the stainless steel hose clamps to secure the flexible moved, reinstall the air and vent lines per this manual and the coupling in place. SlimFit Boiler Vent Supplement. 11. Verify that all the connections are made with no leaks to complete Inspect air inlet box screen installation.

  • Page 99: Check Expansion Tank

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Annual startup (continued) 2. Verify that boiler vent discharge and air intake are clean and free Following installation, the valve lever must be operated of obstructions. AT LEAST ONCE A YEAR to ensure that waterways are clear.

  • Page 100: Check Control Settings

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Annual startup (continued) Inspect ignition electrode Figure 95 Gas valve and venturi 1. Remove the ignition electrode from the boiler heat ex- changer burner end section. See image at right. Ignition...

  • Page 101: Check Burner Flame

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Annual startup (continued) Perform startup procedure per manual Figure 98 Combustion chamber access cover removal 1. Perform all startup procedures on pages page 90 through page 93. Check burner flame 1. Inspect flame through the observation window using the proce- dure on page 90.

  • Page 102: Check Flue Gas Temperature

    24. Re-install the igniter assembly and flame sensor assembly. Make sure the gaskets are in good condition. 1. Review the SlimFit User’s Information Manual with the owner. 25. Re-attach the wiring connections to the igniter and flame sensor. 2. Emphasize the following to the owner: 26.

  • Page 103: Troubleshooting

    Wiring errors can cause improper and dangerous operation. Always disconnect power to boiler before servicing. Failure to comply could Before calling, always complete the “SlimFit Gas result in severe personal injury, death or substantial Data Collection Sheet” (page 111).

  • Page 104: Checking Temperature Sensors

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Troubleshooting (continued) Check the following: Figure 101 Control circuit fuse block in control harness 1. Space heating: a. Make sure thermostat is calling for heat and contacts (includ- ing appropriate zone controls) are closed.
  • Page 105 (jumpered or welded Interlock). 5. Manual reset may be accomplished by pressing the push button on the Sola module, pressing the SlimFit reset button on top of d. Main Valve is energized. the boiler, or by using the Sola display.
  • Page 106 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Troubleshooting (continued) Figure 103 Sola control History (HOME PAGE BOILER ICON DETAILS HISTORY) Sola Lockout History The Sola is able to record information about the boiler’s condition at the time of up to 15 previous lockouts. This information is available to view in the HISTORY menu.
  • Page 107 Is the SlimFit ON/OFF POWER SWITCH • Turn the SlimFit power switch on top of the boiler to ON. located on top of the boiler turned on? Check for 120 volts at the line voltage • Correct wiring inside the control pod using the wiring diagram terminal block located inside the control in this manual.
  • Page 108 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Troubleshooting (continued) Figure 103 Troubleshooting suggestions for SlimFit boilers (continued) Display Condition Diagnostics Corrective actions Inlet/outlet Occurs when a return Manual reset required. • Verify proper flow direction of the boiler pump. This pump...
  • Page 109 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Troubleshooting (continued) Figure 103 Troubleshooting suggestions for SlimFit boilers (continued) Display Condition Diagnostics Corrective actions Light off rate Blower unable to Requires a manual reset. • Check wire harness for loose connections and pin engagement proving failed;...
  • Page 110 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Troubleshooting (continued) Figure 103 Troubleshooting suggestions for SlimFit boilers (continued) Display Condition Diagnostics Corrective actions ILk OFF (gas Low gas pressure Requires manual reset of low gas • Check gas supply pressure, adjust regulator to specification...
  • Page 111 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler SlimFit Gas Boiler Data Collection Sheet Customer Info: Job Info: Contact: Job name: Contractor: Job address: Distributor: City, state: Boiler/System Piping Details (Please Sketch) Maintenance Info: Please note the placement of system sensors...

  • Page 112: Maintenance

    Inspect cleanout plate gasket 4. Use ONLY the cleaning product available from Weil-McLain, Sentinel X400. See the Repair Parts section at the end of this 1. Inspect the cleanout plate gasket (Figure 104, page 113). Replace manual for ordering information.
  • Page 113 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Maintenance (continued) Figure 104 Figure 105 Cleanout plate removal/re-installation Using the cleaning tool Silicone cord must start/end at top center 45° Down Cleanout plate Cleanout plate gasket Horizontal Silicone cord gasket Re-install cleanout plate 1.
  • Page 114 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Maintenance (continued) Figure 106 Cleanout plate nut tightening sequences Gradually tighten the cleanout plate nuts in the sequence shown in Figure 106 until torque reaches 18 N-m/160 in-lbs/13 ft-lbs. If the tightening is not done using...

  • Page 115: Replacement Parts

    ™ 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 116 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Replacement parts Go to www.weil-mclain.com to locate Weil-McLain distributors (continued) Figure 108 Jacket parts Part Number for Item Description SlimFit 550/750 426-700-330 Jacket side post with mounting plate 383-600-249...
  • Page 117 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Replacement parts (continued) Figure 109 Jacket parts Part number 550-100-116/0713...
  • Page 118 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Replacement parts Go to www.weil-mclain.com to locate Weil-McLain distributors (continued) Figure 110 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 119 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Replacement parts (continued) Figure 111 Heat exchanger Part number 550-100-116/0713...
  • Page 120 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Replacement parts Go to www.weil-mclain.com to locate Weil-McLain distributors (continued) Figure 112 Burner, blower, venturi and gas train Item Description Part Number Piping end combustion chamber access plate kit (plate, gasket, insulation, hardware) (Not...
  • Page 121 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Replacement parts (continued) Figure 113 Burner, blower, venturi and gas train Part number 550-100-116/0713...
  • Page 122 LWCO test switch (black button) (part of control wiring harness) Not available Control circuit fuse (2-amp, 24-volt) (not shown) (part of control wiring harness) 591-850-191 Flame sensor kit 383-600-300 Go to www weil-mclain com to locate Weil-McLain distributors Part number 550-100-116/0713...
  • Page 123 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Replacement parts (continued) Figure 115 Controls Part number 550-100-116/0713...

  • Page 124: Dimensions

    SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Dimensions Figure 116 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 125 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Dimensions (continued) Figure 117 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” nominal P/T gauge connection, ½”...

  • Page 126: Ratings - Slimfit Boilers

    Ratings shown are for seal level applications only. For altitudes Combustion efficiency is based on AHRI testing procedure above sea level, the SlimFit boiler requires no modifications and au- BTS-2000, and equal to 100% minus flue loss. tomatically de-rates itself by approximately 4% per 1,000 feet above sea level.
  • Page 127 SlimFit — Boiler Manual ™ commercial condensing gas fired water boiler Notes Part number 550-100-116/0713...

  • Page 128: Installation And Service Certificate

    SlimFit SlimFit — Boiler Manual — Boiler Manual ™ ™ commercial condensing gas commercial condensing gas fired water boiler fired water boiler Installation and Service Certificate Boiler Model Series CP Number Date Installed BTU Input Installation instructions have been followed.

This manual is also suitable for:

Slimfit sf1000lSlimfit sf1500lSlimfit sf2000lSlimfit sf1000rSlimfit sf1500rSlimfit sf2000r

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