Weil-McLain Evergreen 220 User Manual
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Weil-McLain Evergreen 220 User Manual

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See also: Advanced Manual , User's Information Manual
™
CONDENSING GAS BOILER
220/299/300/399
Boiler Manual
This manual must only be used by a qualified heating installer/service technician. Read all instructions, includ-
ing 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 550-100-131/0715

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  • Page 1 ™ CONDENSING GAS BOILER 220/299/300/399 Boiler Manual This manual must only be used by a qualified heating installer/service technician. Read all instructions, includ- ing this manual and all other information shipped with the boiler, before installing. Perform steps in the order given.

  • Page 2: The Evergreen Gas-Fired Water Boilers

    — Boiler Manual ™ FIRED WATER BOILER The Evergreen Gas-fired water boilers The Evergreen control can operate a single boiler or coordi- nate with other Evergreen boilers in a multiple boiler system. The advanced blower design and air inlet silencer on Evergreen boilers result in very quiet operation.
  • Page 3 — Boiler Manual ™ FIRED WATER BOILER The Evergreen Gas-fired water boiler (continued) Low voltage Line voltage – 3 – Part number 550-100-131/0715...

  • Page 4: Table Of Contents

    — Boiler Manual ™ FIRED WATER BOILER Contents The Evergreen Gas-fired water boilers ... . 2 Please read before proceeding ....5 DO NOT SERVICE THE BOILER WITHOUT A Evergreen Boiler location .

  • Page 5: Please Read Before Proceeding

    Use only the products listed by Weil-McLain for use with this boiler. See page 85 for details. Sidewall vent air installations — see instruction on page 20.

  • Page 6: Boiler Location

    — Boiler Manual ™ FIRED WATER BOILER Boiler location Installations must comply with: Locate or protect the boiler so it cannot be damaged by a moving vehicle. Local, state, provincial, and national codes, laws, regulations and ordinances. Ensure that the installation complies with all applicable codes.
  • Page 7 — Boiler Manual ™ FIRED WATER BOILER Boiler location (continued) Provide clearances for service Provide clearances from combustible access — RECOMMENDED materials — REQUIRED 1. See Figure 1 for recommended service clearances. 1. See Figure 2 for REQUIRED minimum clearances. ALL installa- tion must provide at least these minimums.

  • Page 8: Prepare Boiler Location

    Wall-mounted boilers inch lag bolts or ¼” diameter for 3/16-inch toggle bolts. 1. Boilers can be wall mounted ONLY if using the optional wall- RECOMMENDED for drywall or plaster lathe. mount kit available from Weil-McLain. – 8 – Part number 550-100-131/0715...
  • Page 9 (or equivalent wood structure if studs are not on 16-inch centers). The operating weights for Evergreen models are: Evergreen 220: Evergreen 299/300: Evergreen 399: Failure to comply with above and the procedure given below could result in severe personal injury, death or substantial property damage.

  • Page 10: Boiler Hydrostatic Test

    — Boiler Manual ™ FIRED WATER BOILER Wall-mounting the Boiler hydrostatic test boiler (continued) . This is the maximum allowable relief valve setting for the Evergreen boiler. Failure to comply could If upper spacer board is used, install the lower prevent the relief valve from operating as needed, resulting spacer board as shown in Figure 5, page 9.
  • Page 11 — Boiler Manual ™ FIRED WATER BOILER Boiler hydrostatic test (continued) Install piping fittings for relief valve and Install piping components required for pressure/temperature gauge –– hydrostatic test (see legend below) (see legend below) Piping to system Recommended but not included Piping from system Legend for Hydrostatic Testing...

  • Page 12: Gas Conversions

    — Boiler Manual ™ FIRED WATER BOILER Gas conversions Boiler hydrostatic test (continued) 7. When water begins to exit from the supply outlet, Prepare boiler for propane — close the boiler drain valve (item 12). Evergreen ™ 220/299/300/399 (if required) 8.
  • Page 13 — Boiler Manual ™ FIRED WATER BOILER Gas conversions (continued) Natural Gas to Liquefied Petroleum (Propane) conversion kits (continued) Follow all instructions in proper order. Do not tamper with venturi. DO NOT change or modify P/N 383-900-065 NG to Propane Gas Conversion Kit contents: venturi in any way.
  • Page 14 — Boiler Manual ™ FIRED WATER BOILER Gas conversions (continued) 7. Loosen swivel nut (Figure 11, item 7) on venturi-gas valve for Figures 11, 12, 13 and 14 connection (item 6). See Figure 12. Gently set gas valve a side. Air Silencer Gas valve Air silencer clips (2)
  • Page 15 — Boiler Manual ™ FIRED WATER BOILER Gas conversions (continued) swivel nut. Replace silencer gasket and re-attach air silencer LP to Natural gas conversion to venturi. See Figure 14, page 14. 1. Follow the same instructions as LP conversion, except using the correct Natural gas conversion kit, See Figure 8, page 12 .

  • Page 16: Gas Piping - Sizing Gas Lines

    — Boiler Manual ™ FIRED WATER BOILER Gas piping — sizing gas lines Boiler gas connection is ¾” NPT. Size gas lines Pipe capacity for 0.60 specific gravity natural large enough to provide gas to all connected gas; pipe length is in equivalent feet (for non- appliances.

  • Page 17: Venting/Air Piping - General

    — Boiler Manual ™ FIRED WATER BOILER Venting/air piping — general Evergreen Do not install the boiler into a common vent with any other appliance. This will cause flue gas spillage or Install air inlet piping for the Evergreen appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.
  • Page 18 Maximum vent lengths apply for either 3” or 4” vent and air pipe. If using 3” pipe, provide 4”x 3” tapered reducers at boiler connections and at Weil-McLain vent/air cap or at concentric terminations. Boilers will derate as vent/air pipe length increases — see rating data on Figure 120, page 127 for derate amounts.
  • Page 19 BIRD SCREEN at each termination the bird screens. Purchase bird screens separately from Weil-McLain or vent kit supplier if not included. [Note — bird screening is integral to the 3” and 4” PVC Weil-McLain sidewall vent cap, purchased separately. No additional screening is required.] –...

  • Page 20: Commonwealth Of Massachusetts Installations

    — Boiler Manual ™ FIRED WATER BOILER Commonwealth of Massachusetts installations 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, whole or in part for residential purposes, including those the inspector observes carbon monoxide detectors and...

  • Page 21: Vent Termination Requirements

    — Boiler Manual ™ FIRED WATER BOILER Vent termination requirements The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance from adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/ CSA B149.1.

  • Page 22: Boiler Room Air Openings

    — Boiler Manual ™ FIRED WATER BOILER Boiler room air openings ™ Evergreen Combustion and ventilation air openings for Direct Vent installations. Provisions for combustion and ventilation air to be n accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes.

  • Page 23: Direct Vent - Sidewall With Separate Pipes

    — Boiler Manual ™ FIRED WATER BOILER DIRECT VENT — Sidewall with separate pipes — Separate pipes sidewall Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapt- ers if specified. 1. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Fig- ure 20, page 18.
  • Page 24 3. Use the provided paper template for correct location of hole centers. 4. Use of a sidewall termination plate is REQUIRED. a. Kits for several vent sizes are available from Weil-McLain. See “VENT/AIR PARTS AND KITS” on page 115. b. Plate may be field fabricated from corrosion resistant material of sufficient strength.

  • Page 25: Direct Vent - Sidewall With W-M Vent/Air Plate

    Prepare the sidewall penetrations and secure the sidewall plates 1. When terminating multiple Evergreen boilers, ter- as instructed in this section. See “Install Weil-McLain vent/air minate each vent/air connection as described in this cap” on page 26. manual.
  • Page 26 Hole preparation in wall — INSIDE VIEW (use template provided) For the Weil-McLain plate, the template must be level to ensure the flue and air pipe will be side-to-side, as shown in Figure 29. Failure to comply could result in severe personal injury, death or substantial property damage.

  • Page 27: Direct Vent - Sidewall Concentric

    — Boiler Manual ™ FIRED WATER BOILER DIRECT VENT — Sidewall concentric are for the WM 3” and 4” PVC Concentric Kit. If using Simpson-Duravent or Centrotherm — Concentric Concentric kit, please refer to the manufacturer’s installation horizontal instructions. 1. The concentric termination kit must be purchased sepa- rately.
  • Page 28 — Boiler Manual ™ FIRED WATER BOILER DIRECT VENT — Sidewall concentric (continued) See notices on previous page. Termination location — concentric termination — multiple boilers — clearance from vent of one to air intake of the next 1. Assemble the vent termination as described for concentric ter- minations, on page 33.

  • Page 29: Direct Vent - Vertical With Separate Pipes

    — Boiler Manual ™ FIRED WATER BOILER DIRECT VENT — Vertical with separate pipes Separate pipes vertical termination Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapters if specified. 1. Locate the terminations such that the total air pip- ing and vent piping from the boiler to the termina- tion will not exceed the maximum length given in Figure 20, page 18.
  • Page 30 — Boiler Manual ™ FIRED WATER BOILER DIRECT VENT — Vertical with separate pipes (continued) See notices on previous page. Terminations for multiple boilers 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

  • Page 31: Direct Vent - Vertical Concentric

    — Boiler Manual ™ FIRED WATER BOILER DIRECT VENT — Vertical concentric — Concentric vertical 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapters if specified.
  • Page 32 — Boiler Manual ™ FIRED WATER BOILER DIRECT VENT — Vertical concentric (continued) See notices on previous page. Vertical termination — concentric termination — single or multiple boilers 2. Place roof penetrations to obtain minimum of 12 inches between centers of adjacent vent pipe of another boiler for U. S. installa- tions (see Figure 37).

  • Page 33: Concentric Termination, Typical (Sidewall Or Vertical)

    — Boiler Manual ™ FIRED WATER BOILER Concentric termination, typical (sidewall or vertical) concentric termination assembly — DO NOT — Inner PVC pipe (vent) attach the rain cap until the termination has been Outer PVC pipe (air) Y fitting inserted through the roof or wall and all supports Rain cap Finished assembly have been installed.

  • Page 34: Direct Vent - Vertical Vent / Sidewall Air

    — Boiler Manual ™ FIRED WATER BOILER DIRECT VENT — Vertical vent / sidewall air — Vertical vent/ sidewall air Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapters if specified. 1. Locate the terminations such that the total air pip- ing and vent piping from the boiler to the termina- tion will not exceed the maximum length given in Figure 20, page 18.
  • Page 35 — Boiler Manual ™ FIRED WATER BOILER DIRECT VENT — Vertical vent / sidewall air (continued) Vent termination (through the roof) for 1. The air inlet of an Evergreen boiler is part of a direct vent con- direct vent: vertical vent / sidewall air nection.

  • Page 36: Vent And Air Piping And Boiler Connections

    — Boiler Manual ™ FIRED WATER BOILER Vent and air piping and boiler connections Follow termination instructions Boiler vent and air connections Read and follow all instructions for the termination type used before proceeding with this page. Follow all instructions provided by vent pipe manufacturer.

  • Page 37: Install Water Piping

    Use two wrenches when tightening water piping See Replacement parts section at the end of this manual for the Weil-McLain low water cut-off kit. at boiler, using one of the wrenches to prevent the boiler interior piping from turning. Failure to 4.

  • Page 38: System Water Piping Methods

    2. Size the piping and components for each circuit in the space The boiler circulator (Taco 0014 for Evergreen 220, 299 and heating system using Figure 46, page 39. 300; Taco 0013 for Evergreen 399) is shipped loose. Locate it in the boiler outlet, as shown in the appropriate piping diagram in this manual.

  • Page 39: Install Relief Valve

    299/300/399 on the boiler supply piping tee (Fig- throughout its entire length. ure 6, page 11). The Evergreen 220, 299 and 300 boilers come shipped loose with a 30 PSIG, 375 MBTU relief valve. Discharge line must pitch downward from the The Evergreen 399 boiler comes shipped loose with a 30 valve and terminate at least 6”...

  • Page 40: Expansion Tank

    41. Ensure that the expansion tank size will handle boiler and system water volume and temperature. Allow 4.6 gallons for Evergreen 220, 7.0 gallons for Evergreen 299/300 and 6.7 gallons for Evergreen 399. See tank manu- facturer’s instructions and ratings for details.

  • Page 41: System Piping

    Section 303 of the 2007 Energy Act. See page 127 for compliance information and exemptions. Controlling the circulators For more than 3-zones, use Weil-McLain WMZV zone valve 1. The control can control up to four circulators (boiler circulator controller.
  • Page 42 Refer to Field wiring, beginning on page 50, for page 50, for details. instructions on wiring to circulators. 3. For more than 3-zones, use Weil-McLain WMCR zone Circ 2. The factory default settings are: all three inputs are set up for controller.
  • Page 43 See page 127 to ensure compliance with the 2007 Energy Act. For more than 3-zones, use Weil-McLain WMCR zone Circ controller. 3. DHW Priority operation—The Control turns off space heating to the HEAT zones during domestic water heating The Control can operate the Hi-Temp Zones and Low-Temp Zones calls on the DHW input.
  • Page 44 DHW mode when system is intended for space heat- page 50, for details. ing may violate Section 303 of the 2007 Energy Act. See 3. For more than 3-zones, use Weil-McLain WMCR zone Circ page 127 for compliance information and exemptions. controller.
  • Page 45 1. The control can control up to four circulators (boiler circulator and three others). Refer to Field wiring, beginning on page 50, 3. For more than 3-zones, use Weil-McLain WMCR zone for instructions on wiring to circulators. Circ controller. See EVG Advanced Manual for proper wiring.
  • Page 46 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 84 for details. Chilled medium, if used, is piped in parallel with heating boiler as shown in Figure 54.

  • Page 47: Install Condensate Line

    — Boiler Manual ™ FIRED WATER BOILER Install condensate line Prepare condensate fittings Condensate trap assembly 1. Remove PVC fittings and gasket from the accessories bag. 2. Deburr and chamfer outside and inside of ½” PVC nipple to ensure even cement distribution when joining. 3.
  • Page 48 (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. Suggested condensate pump capacity, GPH EVG 220...

  • Page 49: Gas Piping

    — Boiler Manual ™ FIRED WATER BOILER Gas piping Connect gas supply piping Evergreen boilers are shipped ready to fire natural gas ONLY. You must install the propane ven- turi if the boiler will be connected to propane. See page 12. Failure to comply could result in severe per- sonal injury, death or substantial property damage.

  • Page 50: Field Wiring (See Wiring Diagram, Figure

    — Boiler Manual ™ FIRED WATER BOILER Field wiring (see wiring diagram, Figure 62, page 57) Field wiring overview (see Figure 62, page 57 and Figure 63, page 58 for detailed schematic and ladder — For your safety, turn off wiring diagrams) electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard.
  • Page 51 — Boiler Manual ™ FIRED WATER BOILER Field wiring (see wiring diagram, Figure 62, page 57)(continued) A. 120 VAC Power Supply – REQUIRED (control tray, right front) 1. Provide and install a properly sized fused disconnect or service switch as required by applicable codes. (15-amp for most cases.) Boiler &...
  • Page 52 — Boiler Manual ™ FIRED WATER BOILER Field wiring (see wiring diagram, Figure 62, page 57)(continued) – REQUIRED (control tray, left side) 1. Provides 120VAC to the boiler circulator at Pump/Comm Board P8 Terminals. 2. Terminals are: 1 (H), 2 (N), 3 (G). 3.
  • Page 53 — Boiler Manual ™ FIRED WATER BOILER Field wiring (see wiring diagram, Figure 62, page 57)(continued) – REQUIRED (EVG control module, left side) 1. Two strap-on temperature sensors are shipped with the 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 faster response.
  • Page 54 1. Install a low water cut-off when required. 2. Wiring Weil-McLain LWCO Kit: a. When possible, use the Weil-McLain Low water cut-off kit listed in the back of this manual. It includes a probe-type low water cut-off and pro- vides a simple harness connection for the wiring.
  • Page 55 — Boiler Manual ™ FIRED WATER BOILER Field wiring (see wiring diagram, Figure 62, page 57)(continued) K. Proof of closure (flow switch and/or CAD) – – see ADVANCED Manual OPTIONAL (EVG control, bottom left of center) 1. A flow switch or combustion air damper (CAD) interlock can be configured by clipping the jumper on terminal strip P7 and wiring components as shown at right and in the wiring diagram (Figure 62, page 57).
  • Page 56 — Boiler Manual ™ FIRED WATER BOILER Field wiring (see wiring diagram, Figure 62, page 57)(continued) M. 0–10 VDC Remote MODULATION input – OPTIONAL (EVG control module, left side) 1. See illustration at right and Figure 62, page 57 for details. 2.

  • Page 57: Wiring Diagram - Schematic

    — Boiler Manual ™ FIRED WATER BOILER Wiring diagram — schematic Evergreen schematic wiring diagram (see Figure 63, page 58 for legend and notes) – 57 – Part number 550-100-131/0715...

  • Page 58: Wiring Diagram - Ladder

    — Boiler Manual ™ FIRED WATER BOILER Wiring diagram — ladder Evergreen ladder wiring diagram (see Figure 62, page 57 for schematic wiring diagram) – 58 – Part number 550-100-131/0715...

  • Page 59: Zoning With The Evg Control

    — Boiler Manual ™ FIRED WATER BOILER Zoning with the EVG Control A. Zoning with CIRCULATORS, suggested applications 1. Review wiring information on page 51 (120VAC out- puts) and page 52 (24VAC inputs). 2. The configuration at right uses the three input/output pairs to receive thermostat inputs on P11-4/5, P15-1/2, and P15-3/4;...
  • Page 60 — Boiler Manual ™ FIRED WATER BOILER Zoning with the EVG Control (continued) B. Zoning with ZONE VALVES, suggested applications 1. Review wiring information on page 51 (120VAC outputs) and page 52 (24VAC inputs). 2. The configuration at right uses INPUT 2 and 3 for space heating thermostats.

  • Page 61: Evergreen Control Operation

    — Boiler Manual ™ FIRED WATER BOILER Evergreen Control operation Control sequence of operation Evergreen control setup 1. Set control parameters using the WIZARD option provided on initial start-up or manually enter parameters using control menus (see Figure 71, page 73 and following pages for information.) (also see Figure 68, page 65) 2.
  • Page 62 — Boiler Manual ™ FIRED WATER BOILER Evergreen Control operation (continued) EVG control Priorities & Input/Outputs Setting Up the Boiler For heating installations with multiple systems, the EVG control uses PRIORITIES to determine the order of operation of the systems. The control’s MAX and MIN time settings determine the Step 1 maximum and minimum times a system will be operated before being turned off to allow another system to operate.

  • Page 63: Outdoor Reset Operation

    — Boiler Manual ™ FIRED WATER BOILER Evergreen Control operation (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 65. 3.
  • Page 64 — Boiler Manual ™ FIRED WATER BOILER Evergreen Control operation (continued) Evergreen single boiler essential settings ( on initial start-up) — see page 72 for explanation – 64 – Part number 550-100-131/0715...
  • Page 65 — Boiler Manual ™ FIRED WATER BOILER Evergreen Control operation (continued) Evergreen control display screens and typical navigation – 65 – Part number 550-100-131/0715...

  • Page 66: Express Setup - Example A

    — Boiler Manual ™ FIRED WATER BOILER EXPRESS SETUP — E XAMPLE DHW (Direct-piped) SPACE HEATING — VALUE MUST BE SET OR VERIFIED EVG C ONTROL SETTINGS D — DEFAULT ACCEPTABLE CHANGE ONLY IF WIZARD IN ORDER OF SEQUENCES Failure to set correctly could result in severe DESIRED personal injury, death or substantial property damage.
  • Page 67 — Boiler Manual ™ FIRED WATER BOILER EXPRESS SETUP — E XAMPLE (continued) DHW (Direct-piped) SPACE HEATING Unions as needed Evergreen boiler. for service. Indirect water heater, if Return tempera- used (domestic water ture sensor. piping not shown) — MUST be direct piped to boiler to use default Supply tempera- control settings.

  • Page 68: Express Setup - Example B

    — Boiler Manual ™ FIRED WATER BOILER EXPRESS SETUP — E XAMPLE DHW (Direct-piped) SPACE HEATING — VALUE MUST BE SET OR VERIFIED EVG C ONTROL SETTINGS D — DEFAULT ACCEPTABLE CHANGE ONLY IF WIZARD IN ORDER OF SEQUENCES Failure to set correctly could result in severe DESIRED personal injury, death or substantial property damage.
  • Page 69 — Boiler Manual ™ FIRED WATER BOILER EXPRESS SETUP — E XAMPLE (continued) DHW (Direct-piped) SPACE HEATING Unions as needed Evergreen boiler. for service. Indirect water heater, if Return tempera- used (domestic water ture sensor. piping not shown) — MUST be direct piped to boiler to use default Supply tempera- control settings.

  • Page 70: Express Setup - Example C

    — Boiler Manual ™ FIRED WATER BOILER EXPRESS SETUP — E XAMPLE DHW (Direct-piped) SPACE HEATING — VALUE MUST BE SET OR VERIFIED EVG C ONTROL SETTINGS D — DEFAULT ACCEPTABLE CHANGE ONLY IF WIZARD IN ORDER OF SEQUENCES Failure to set correctly could result in severe DESIRED personal injury, death or substantial property damage.
  • Page 71 — Boiler Manual ™ FIRED WATER BOILER EXPRESS SETUP — E XAMPLE (continued) DHW (Direct-piped) SPACE HEATING Zone valves. Evergreen boiler. Unions as needed Indirect water heater, if for service. used (domestic water piping not shown) — Return tempera- MUST be direct piped ture sensor.

  • Page 72: Available Control Settings And System Presets

    — Boiler Manual ™ FIRED WATER BOILER Available control settings and system presets Evergreen 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) Source (TT1 or 0-10v)

  • Page 73: Contractor Menus

    — Boiler Manual ™ 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 74: Boiler Settings Menu, Basic Mode

    — Boiler Manual ™ 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 75: Priority 1, 2, 3 Menus, Basic Mode

    — Boiler Manual ™ 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 76: Assign Inputs Menu, Basic Mode

    — Boiler Manual ™ 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 77 — Boiler Manual ™ FIRED WATER BOILER ASSIGN INPUTS menu, BASIC mode (continued) AUX PUMP/OUTPUT operation (accessed in ASSIGN INPUTS menu – see Figure 74, page 76) Hot loop for seasonal boilers that are manually Output is always energized whenever the control is powered. shut down at end of season and started up at start of heating season.

  • Page 78: Diagnostic Menu

    — Boiler Manual ™ FIRED WATER BOILER DIAGNOSTIC menu menu navigation (see Figure 68, page 65 for access information) Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data DIAGNOSTICS TEMPERATURES STATUS: ########## º BOILER OUT1: º...
  • Page 79 — Boiler Manual ™ FIRED WATER BOILER DIAGNOSTICS menu (continued) menu navigation, continued (see Figure 68, page 65 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 80 — Boiler Manual ™ FIRED WATER BOILER DIAGNOSTICS menu (continued) menu details (see Figure 68, page 65 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 t he first sensing element of the boiler’s heat exchanger outlet sensor...
  • Page 81 — Boiler Manual ™ FIRED WATER BOILER DIAGNOSTICS menu (continued) menu details (continued) (see Figure 68, page 65 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. Displays cumulative time that Input 1 has been closed (Or 0-10V t 1 volt) Displays cumulative time that Input 2 has been closed Displays cumulative time that Input 3 has been closed...
  • Page 82 — Boiler Manual ™ FIRED WATER BOILER DIAGNOSTICS menu (continued) menu details (continued) (see Figure 68, page 65 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 83: Maintenance, Date And Time Menus

    — Boiler Manual ™ FIRED WATER BOILER MAINTENANCE, DATE AND TIME menus menus — navigation (see Figure 68, page 65 for access information) Name Contractor name to appear in maintenance reminders and during lockouts Phone Contractor phone number Model Displays the boiler model selected in the boiler setup CP Number Enter the CP# of the boiler Installed...

  • Page 84: Startup - Fill The System

    Manometer Measure the INLET gas pressure to the boiler (Inclined or digital) 1. Use only antifreeze listed by Weil-McLain as suitable for use Combustion analyzer Combustion testing and boiler adjustments Evergreen with Gas Boilers. See Figure 108, page 115 for (Digital preferred) information.
  • Page 85 Weil-McLain. 3. Test antifreeze concentration. Weil-McLain provides information for Test antifreeze concentration at least annually. If concentra- application of the antifreeze products tion is low, add antifreeze or drain system and refill with listed in this document only for use in correct mixture.

  • Page 86: Startup - Final Checks

    — Boiler Manual ™ FIRED WATER BOILER Startup — final checks Check for gas leaks 1. Loosen the hose clamp securing the right end of the condensate trap to the PVC reducing elbow (see page 47 for details). Before starting the boiler, and during initial operation, 2.
  • Page 87 — Boiler Manual ™ FIRED WATER BOILER Startup — final checks (continued) Operating instructions (WARNING — Verify that the Control is set for the correct boiler model before proceeding.) – 87 – Part number 550-100-131/0715...
  • Page 88 Check around the boiler and inside the boiler jacket for gas odor contact your local Weil-McLain representative. following the procedure of page 49 of this manual. Throttle screw adjustment must be done only If you discover evidence of any gas leak, shut down the boiler at once.

  • Page 89: Gas Valve Adjustment

    Weil-McLain representative. 4. Should you require any assistance during the set up procedure contact your Weil-McLain representative if the problem cannot be addressed with the information provided in this manual. Make sure the Max firing rate is set to the maximum and confirm the ❏...

  • Page 90: Check-Out/Startup Verification

    Replace any damaged gasket. 1. Operate the boiler on HIGH fire. d. Contact your Weil-McLain representative if the problem 2. Using an inspection mirror, move the mirror around all heat cannot be addressed with the information provided in exchanger joints and vent pipe connections at the top of the this manual.

  • Page 91: Annual Startup And General Maintenance

    — Boiler Manual ™ FIRED WATER BOILER Annual startup and general maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

  • Page 92: Annual Startup

    — Boiler Manual ™ FIRED WATER BOILER Annual startup FIRST-YEAR SPECIAL ANNUAL STARTUP INSPECTION 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 87, page 91 and explained on the follow- ing pages must be performed to assure maximum boiler efficiency and reliability.
  • Page 93 — Boiler Manual ™ FIRED WATER BOILER Annual startup (continued) Address reported problems DO NOT SERVICE THE BOILER Inspect any problems reported by owner and correct before proceeding. Evergreen WITHOUT AN INSPECTION KIT AVAILABLE Inspect boiler area 1. Verify that boiler area is free of any combustible materials, Before each annual inspection, obtain an EVG Inspection gasoline and other flammable vapors and liquids.
  • Page 94 — Boiler Manual ™ FIRED WATER BOILER Annual startup (continued) Make sure a closed-type tank is fitted with a tank fit- Check all piping for leaks ting, such as the B & G Tank-Trol or Taco Taco-Trol. Eliminate all system or boiler leaks. Continual fresh This fitting reduces gravity circulation of air-saturated make-up water will reduce boiler life.
  • Page 95 — Boiler Manual ™ FIRED WATER BOILER Annual startup (continued) 3. Remove the air baffle (item 2) and screws (item 4) from the c. If the flame sense rod is bent or cannot be cleaned satis- factorily or if the ceramic is cracked or damaged, replace jacket top as shown.
  • Page 96 — Boiler Manual ™ FIRED WATER BOILER Annual startup (continued) Accessing burner, ignition electrode, flame sense rod and inspection glass assembly (EVG 220 shown) Boiler interior assembled view (Model EVG 220 shown; component locations vary with other models) Boiler interior exploded view, showing heat exchanger cover plate (item 6) blower, burner assembly, burner access cover seal (item 13), ignitor, flame sense rod, and sight glass.

  • Page 97: Check Control Settings

    2. Verify cold fill pressure is correct and that operating pressure ment burner from Weil-McLain. does not go too high. Adjust water pressure and expansion 7. Check flame signal at both high fire and low fire.
  • Page 98 — Boiler Manual ™ FIRED WATER BOILER Annual startup (continued) Check blower speeds Firing rates and corresponding blower speeds (low fire, ignition, and high fire) — for altitudes up to 5,500 feet and 1. For installations at altitudes above 2,000 feet, high altitude (above 5,500 feet).

  • Page 99: Manual Test Mode For Single And Multiple Boilers

    — Boiler Manual ™ FIRED WATER BOILER Annual startup (continued) Manual Test Mode for Single and Check boiler relief valve Multiple Boilers 1. Inspect the relief valve and lift the lever to verify Single Boiler flow as in the following warnings, excerpted from 1.

  • Page 100: Troubleshooting

    — Boiler Manual ™ FIRED WATER BOILER Troubleshooting Before calling for troubleshooting assistance, fill in the “ ” (page 130). 1. See below for tools and kits recommended for troubleshooting Evergreen boilers. Record the boiler size and CP number (located on the out- 2.

  • Page 101: Checking Temperature Sensors

    — Boiler Manual ™ FIRED WATER BOILER Troubleshooting (continued) 5. If necessary, replace one or all of the fuses: Check Control fuses ALWAYS check control fuses before replacing a. Item 1 - Boiler Circ fuse is a 3-amp fast-blow (Littelfuse control or any major components (blower, etc.).
  • Page 102 — Boiler Manual ™ FIRED WATER BOILER Troubleshooting (continued) Control fault indications 1. The control provides diagnostic infor- 2. Figure 97 shows the screen behavior 3. Figure 98, page 103 lists conditions mation for both automatic reset con- during a fault condition. The display that will cause the control to display ditions and manual reset conditions.
  • Page 103 — Boiler Manual ™ FIRED WATER BOILER Troubleshooting (continued) 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 72, page 74. for a specified length of time.
  • Page 104 — Boiler Manual ™ FIRED WATER BOILER Troubleshooting (continued) Evergreen Troubleshooting suggestions for boilers — Condition Diagnostics Corrective Action(s) Display Nothing shown on display to the control. screen and boiler will not respond to call for heat Check transformer connection of transformer.
  • Page 105 — Boiler Manual ™ FIRED WATER BOILER Troubleshooting (continued) Evergreen Troubleshooting suggestions for boilers — Condition Diagnostics Corrective Action(s) Display LOW WTR CUTOFF OPEN contacts are open at least one refer to piping section of this manual. Manual reset of control if contacts are open longer than 5 seconds.
  • Page 106 — Boiler Manual ™ FIRED WATER BOILER Troubleshooting (continued) Evergreen Troubleshooting suggestions for boilers — Condition Diagnostics Corrective Action(s) Display LIMIT OPEN reset l imit op ens. reset 2½ minutes after external external limit to determine and correct the cause that opened the limit. limit device closes.
  • Page 107 — Boiler Manual ™ FIRED WATER BOILER Troubleshooting (continued) Evergreen Troubleshooting suggestions for boilers — Condition Diagnostics Corrective Action(s) Display IGNITION FAULT attempts and never detected inside heat exchanger. flame or flame sense value never reached minimum part. poor ignition. to diagnose condition.

  • Page 108: Maintenance

    This is particularly important if the boiler is 1. Isolate the boiler from the heating system. located in the same room as other appliances. 2. Obtain Sentinel X400 cleaner from Weil-McLain. Follow Inspect boiler jacket door gaskets. Gaskets instructions supplied with the cleaner to clean the boiler must be in good condition, with no tears or heat exchanger.

  • Page 109: Cleaning Heat Exchanger Flue Side

    — Boiler Manual ™ FIRED WATER BOILER Cleaning heat exchanger flue side The boiler contains ceramic fiber materials. Use Remove the burner access panel and screws care when handling these materials per instructions (1 and 3) and air baffle and screws (2 and 4) on page 92 of this manual.
  • Page 110 — Boiler Manual ™ FIRED WATER BOILER Cleaning heat exchanger flue side (continued) 4. Remove the heat exchanger cover plate: Inspect combustion chamber and refractory a. See Figure 106, page 113 part A, part B and part C. b. Use a 10 mm wrench or socket to remove the nuts 1.
  • Page 111 — Boiler Manual ™ FIRED WATER BOILER Cleaning heat exchanger flue side (continued) 5. If the vacuum cleaner is unable to clean completely, wash the Placing refractory into heat exchanger and heating surfaces with clean, warm water,using the following applying silicone adhesive – EVG 220 shown procedure.
  • Page 112 — Boiler Manual ™ FIRED WATER BOILER Cleaning heat exchanger flue side (continued) Reinstall components Legend for Figure 106, page 113 1. See Figure 106, page 113 for reference. 2. Obtain the new burner gasket (item 12) from the Maintenance Kit Boiler interior assembled view, and install into the heat exchanger cover plate.
  • Page 113 — Boiler Manual ™ FIRED WATER BOILER Cleaning heat exchanger flue side (continued) Accessing the burner or heat exchanger (see Legend on page 112), (Evergreen 220 shown). – 113 – Part number 550-100-131/0715...

  • Page 114: Replacement Parts

    Replacement parts must be purchased through a local disassembling parts of the boiler. Failure to replace Weil-McLain distributor. When ordering, specify boiler model damaged components and to use only the parts spe- and size and include description and part number of replace- ment part.
  • Page 115 IPEX PVC concentric vent kit — available from burner access cover seal, and hardware IPEX Evergreen 220 maintenance kit — flame sense 383-900-071 196006(L=20”) Kit for 3” PVC vent and air pipes ..
  • Page 116 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen Jacket parts — 220/299/300/399 (see Figure 110, page 117 for illustration) Item Name Description / contents Part Number Front door (Includes W-M badge and door gaskets) 383-900-073 Front door gasket kit Seals for front door to jacket (Includes right, left and top gaskets) 383-900-070 Wall-mount bracket (jacket side)
  • Page 117 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen Jacket assembly — 220/299/300/399 (see Figure 109, page 116 for part numbers) *DVNHW VKRZQ LV SURYLGHG LQ Item 130, pages 119 and 121 Gasket Kit P/N 383-900-028 – 117 – Part number 550-100-131/0715...
  • Page 118 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen Heat exchanger parts 220 (see Figure 112, page 119 for illustration) Item Name Description / contents Part Number Heat exchanger, gaskets and hardware (Includes items 130 and 150) 383-900-025 +HDW H[FKDQJHU FRQGHQVDWH GLVK FRYHU SODWH EXUQHU LJQLWHU VLJKW JODVV UHIUDFWRU\ ZDWHU VHQVRUV JDVNHWV (Includes items 120 through 280)
  • Page 119 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen 220 heat exchanger assembly (see Figure 111, page 118 for part numbers) – 119 – Part number 550-100-131/0715...
  • Page 120 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen Heat exchanger parts 299/300/399 (see Figure 114, page 121 for illustration) Model Model Description / contents Item Name 299/300 383-900-024 — Heat exchanger, gaskets and hardware (Includes items 130, and 150) 383-900-023 —...
  • Page 121 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen 299/300/399 heat exchanger assembly (see Figure 113, page 120 for part numbers) – 121 – Part number 550-100-131/0715...
  • Page 122 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen Piping components for 220/299/300/399 (see Figure 116, page 123 for illustration) Item Name Description / contents 299/300 383-900-027 — *DV YDOYH *DV YDOYH JDVNHW DQG RULQJ 383-900-061 — — 383-900-054 —...
  • Page 123 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen Piping components for 220/299/300/399 (see Figure 115, page 122 for part numbers) – 123 – Part number 550-100-131/0715...
  • Page 124 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen 220/299/300/399 (see Figure 118, page 125 for illustration) Controls & electrical components — Item Name Description / contents Flue temperature sensor One sensor 511-724-292 Outdoor temperature sensor One sensor 510-312-218 6\VWHP WHPSHUDWXUH VHQVRU (2 required)
  • Page 125 — Boiler Manual ™ FIRED WATER BOILER Replacement parts (continued) Evergreen Controls & electrical assemblies — 220/299/300/399 (see Figure 117, page 124 for part numbers) – 125 – Part number 550-100-131/0715...

  • Page 126: Dimensions

    — Boiler Manual ™ FIRED WATER BOILER Dimensions Evergreen Dimensional data — 220/299/300/399 (all dimensions in inches) Boiler supply tapping — 1½” NPT. Gas connection – ¾” NPT (manual gas valve shipped Boiler return tapping — 1½” NPT. loose for field installation) See page 49 for details and instructions.

  • Page 127: Ratings

    As an Energy Star Partner, Weil-McLain for requirements of the building and All vent and air pipe elbows must has determined that Evergreen 220 and nothing need be added for normal be sweep elbows, NOT short-radius 299 boilers meet the Energy Star guide- piping and pickup.

  • Page 128: Ratings - Multiple Boilers

    Based on standard test procedures outlined by DOE for individual boilers. Net water ratings are based on piping and pickup allowance of 1.15. Consult Weil-McLain Technical Services for other allowances. Total amp requirement includes up to three circulators, not exceeding 2.2 amps per circulator.

  • Page 129: Installation And Service Certificate

    — Boiler Manual ™ FIRED WATER BOILER Installation and Service Certificate Evergreen ❏ Installation instructions have been followed. ❏ Check-out sequence has been performed. ❏ Information on next two pages is certified to be correct. ❏ Information received and left with owner/maintenance person. Installer (Company) (Address)

  • Page 130: Gas Boiler Data Collection Sheet

    — Boiler Manual ™ FIRED WATER BOILER Installation and Gas Boiler Data Collection Sheet %RLOHU 0RGHO  6HULHV (9* BBBBBBBB  6HULHV BBBBBBB 'DWH ,QVWDOOHG BBBBBBBBBBBBBBBBBBB &3 1XPEHU BBBBBBBBBBBBBBBBBB )XHO 7\SH 1DWXUDOBBB /3BBB %78 ,QSXW BBBBBBBBBBBB )ODPH VLJQDO RQ FRQWURO GLVSOD\ DW +,*+ ¿UH BBBBBBBBBBBBBBBBB )ODPH VLJQDO RQ FRQWURO GLVSOD\ DW /2: ¿UH BBBBBBBBBBBB :DV YHQWXUL FKDQJHG"...

  • Page 131: Part Number 550-100

    — Boiler Manual ™ FIRED WATER BOILER Installation and Gas Boiler Data Collection Sheet &2 # +LJK )LUHBBBBBB /RZ )LUHBBBBBB &2# +LJK )LUH BBBBB SSP /RZ )LUH BBBBB SSP 1DWXUDO *DV  /3 LQSXW UDWH PHDVXUHG +,*+ BBBBBB &)+  /2:BBBBBBBB &)+ 3ULRULW\  6HWWLQJV 3ULRULW\  6HWWLQJV 3ULRULW\  6HWWLQJV...
  • Page 132 — Boiler Manual ™ FIRED WATER BOILER...

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Evergreen 299Evergreen 300Evergreen 399

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