Weil-McLain SlimFit Commercial Condensing Gas Boiler Manual

Weil-McLain SlimFit Commercial Condensing Gas Boiler Manual
®
Series 3
Models 550 and 750 MBH
Commercial Condensing
Gas-fired water boilers
Boiler Manual
s )NSTALLATION s -AINTENANCE
s 3TARTUP
s 0ARTS
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.
Part number 550-100-168/0516
®
SlimFit Series 3
The
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SlimFit™ Series 3
COMMERCIAL gas-fired water boiler
#AST ALUMINUM SECTIONAL HEAT EXCHANGER
(EAT EXCHANGER CLEANOUT PLATE
"LOWER
Air enters the boiler enclosure through the air intake adapter (18),
flows through the enclosure, enters the air inlet silencer (5), then enters
the venturi (6). The blower pulls air and gas through the venturi and
pushes the mixture into the burner. The advanced blower design and
air inlet silencer yield very quiet operation.
A "LOWER MOTOR
!UTOMATIC GAS VALVE
The automatic gas valve incorporates two solenoid-operated valve
seats. The valve senses the vacuum in the venturi (item 6) caused by
flowing air. Gas flows in proportion to air flow, so fuel/air ratio remains
constant as blower speed/air flow changes.
!IR INLET SILENCER
The horn-shaped air inlet silencer significantly reduces fan noise,
providing exceptionally quiet operation.
6ENTURI
When air flows through the venturi, it creates a vacuum that is sensed
by the gas valve to regulate gas flow (see item 4).
#ONTROL MODULE SEE DISCUSSION UPPER RIGHT
%XPANSION MODULE
The expansion module operates the gas valve, monitors gas pressure
switches and provides a dry contact for the boiler circulator (suitable
for up to 10 amps). Connections for BMS and Boiler-to-Boiler communications also located on board.
4EMPERATURE AND PRESSURE GAUGE
%LECTRONIC DISPLAY BUTTONS
The electronic display is used to configure boiler settings and monitor
boiler operation. The buttons allow changing display mode, entering
setting values, and resetting after lockout.
&LUE PIPE ADAPTER INCH 06# SIZE FEMALE
0REMIX GAS BURNER NOT SHOWN
Made with high-grade stainless steel and fiber mesh construction, the
burner uses pre-mixed air and gas. The burner and control provide
modulating firing.
7ATER OUTLET PIPE SYSTEM SUPPLY
7ATER RETURN PIPE SYSTEM RETURN
'AS CONNECTION PIPE
-ANUAL GAS SHUT OFF VALVE
3WING AWAY CONTROL PANEL ASSEMBLY
The SlimFit control panel is mounted to a hinged sub panel, allowing the panel to be swung forward and down for easy access to the
electrical connections.
!IR INTAKE ADAPTER INCH 06# SIZE FEMALE
%LECTRICAL ENTRANCES KNOCKOUTS
Knockouts are provided in the jacket top panel, allowing conduit entry
directly behind the control panel or near the wall.
!IR PRESSURE SWITCH
,OW WATER CUTOFF
(EAT EXCHANGER mUE GAS CONDENSATE DRAIN
&LUE GAS CONDENSATE DRAIN lELD CONNECTION
&RONT DOOR
The front door is sealed to the boiler assembly around its entire perimeter.
*ACKET DOOR LATCHES
)GNITION ELECTRODEmAME SENSOR
The burner flame is ignited by applying a high voltage to the ignition
electrode. This causes a spark (from electrode to ground). After ignition, the electrode measures flame signal.
2
— Boiler Manual
#ONTROL OVERVIEW
s The control can operate a single boiler or coordinate with other
SlimFit 550/750 Series 3 boilers in a multiple boiler system.
s Control inputs and outputs allow operation of multiple heating circuits (space heating and DHW, for example).
s Up to three priority levels can be set, providing automatic
switch-over on demand.
s This manual provides quick set-up information for single
boiler installations.
s The Advanced Manual, also supplied with the boiler, provides
instructions for setting up multiple-boiler systems and for using advanced options for single boilers.
#ONTROL OPERATION
s The control responds to signals from the room thermostats,
DHW aquastats (if used), boiler sensors (boiler return, boiler
supply, flue temperature), outdoor temperature and system
sensor, if used.
s The control automatically adjusts blower speed (and gas flow
rate) to match boiler output to space heating and/or DHW
heating demand.
s The default control settings provide for three space heating
zones. The control can be easily set up for operation with a
DHW zone, with or without domestic priority.
#ONTROL WIZARD
s The control setup Wizard is available from the BOILER
SETTINGS menu that appears during initial startup.
s The Wizard leads through a step-by-step setup procedure
designed for the application chosen.
s Context-sensitive help is available to explain the purpose of
key setup items.
&LAME INSPECTION WINDOW
The quartz glass window provides a view of the burner surface and
flame.
,INE VOLTAGE TERMINAL STRIP VOLT POWER
/./&& SWITCH
(IGH GAS PRESSURE SWITCH
,OW GAS PRESSURE SWITCH
4RANSFORMER
"LOWER RELAY
#ONTROL TEMPERATURE SENSOR WELL
04 GAUGE PRESSURE SENSOR TAPPING
04 GAUGE TEMPERATURE SENSOR WELL
7IRE HARNESS CONNECTOR LINE VOLTAGE
7IRE HARNESS CONNECTOR LOW VOLTAGE
"LOWER PLATE
A blower plate is used on SF-550 for both natural gas and propane
applications. The SF-750 propane requires a blower plate, but does
not use a blower plate on natural gas.
0ROPANE GAS ORIlCE LOCATION
Boilers are shipped with no orifice installed (not required for natural
gas). The propane orifice must be installed to operate on propane.
"OILER OUTLET TEMPERATURE SENSOR WELL
40 GAUGE TEMPERATURE SENSOR WELL
4APPING PLUGGED NOT USED
40 GAUGE PRESSURE SENSOR TAPPING
Located in bottom of supply manifold.
&LUE INSPECTION PLUG
Part number 550-100-168/0516
®
SlimFit Series 3
The
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SlimFit™ Series 3
Part number 550-100-168/0516
— Boiler Manual
COMMERCIAL gas-fired water boiler
3
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Contents
#ONTENTS 4
&IELD WIRING 50
(AZARD DElNITIONS 4
7IRING $IAGRAMS SEE &IGURE &IGURE 60
0LEASE READ BEFORE PROCEEDING 5
:ONING WITH THE 3LIM&IT #ONTROL 64
0REPARE BOILER LOCATION 6
#ONTROL OPERATION AND SETUP 66
0REPARE BOILER 8
#/.42!#4/2 MENUS 72
)NSTALL WATER PIPING 12
"/),%2 3%44).'3 MENU "!3)# MODE 73
6ENTINGAIR PIPING ˆ -ASSACHUSETTS INSTALLATIONS 20
02)/2)49 MENUS "!3)# MODE 74
6ENTINGCOMBUSTION AIR ˆ GENERAL
!33)'. ).0543 MENU "!3)# MODE
21
75
6ENTINGCOMBUSTION AIR ˆ OPTIONS #ATEGORY )) )6 23
$)!'./34)# MENU 77
!PPLIANCES REMAINING ON AN EXISTING VENT SYSTEM 23
-!).4%.!.#% $!4% !.$ 4)-% MENUS 82
6ENTINGCOMBUSTION AIR ˆ OPTIONS #ATEGORY )) 24
3TARTUP ˆ lLL THE SYSTEM 83
$IRECT %XHAUST #ATEGORY )) /NLY 6ENTING n GENERAL
25
3TARTUP ˆ lNAL CHECKS 85
$IRECT %XHAUST #ATEGORY )) /NLY "OILER ROOM AIR
OPENING 26
/PERATING )NSTRUCTIONS 88
$IRECT %XHAUST #ATEGORY )) /NLY n 6ERTICAL 27
!NNUAL STARTUP AND GENERAL MAINTENANCE 90
$)2%#4 %8(!534 ˆ "OILER ROOM AIR OPENINGS 29
!NNUAL STARTUP 91
$)2%#4 %8(!534 ˆ 3IDEWALL 31
4ROUBLESHOOTING 96
$)2%#4 %8(!534 ˆ 6ERTICAL 34
-AINTENANCE 105
$)2%#4 6%.4 ˆ "OILER ROOM AIR OPENINGS 36
2EPLACEMENT PARTS 108
$)2%#4 6%.4 ˆ 3IDEWALL 38
$IMENSIONS 120
$)2%#4 6%.4 ˆ 6ERTICAL 42
2ATINGS ˆ 3LIM&IT 3ERIES BOILERS 121
)NSTALL VENTAIR PIPING ˆ FROM TERMINATION TO BOILER 45
2ATINGS ˆ MULTIPLE 3LIM&IT 3ERIES BOILERS 122
)NSTALL CONDENSATE COMPONENTS 46
)NSTALLATION AND 3ERVICE #ERTIlCATE 123
'AS PIPING 48
)NSTALLATION AND 'AS "OILER $ATA #OLLECTION 3HEET 124
#HECK OUTSTARTUP VERIlCATION 89
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels or to important information concerning the life of the product.
Indicates presence of hazards that will cause severe personal injury, death or
substantial property damage.
Indicates presence of hazards that can cause severe personal injury, death or
substantial property damage.
Indicates presence of hazards that will or can cause minor personal injury or
property damage.
Indicates special instructions on installation, operation or maintenance that are
important but not related to personal injury or property damage.
4
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Please read before proceeding
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#HEMICAL TREATMENT IS REQUIRED 3EE
PAGE FOR DETAILS
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Commonwealth of
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Part number 550-100-168/0516
s
4HOROUGHLY mUSH THE SYSTEM (with-
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5
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Prepare boiler location
Installations must comply with:
s
s
s
s
s
&IGURE Clearances
Local, state, provincial, and national codes, laws, regulations and
ordinances.
National Fuel Gas Code, ANSI Z223.1 – latest edition.
Standard for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1, when required.
National Electrical Code.
For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.
The SlimFit boiler gas manifold and controls met safe
lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13 — latest edition.
Before locating the boiler, check:
1. Check for nearby connection to:
s System water piping
s Venting connections
s Gas supply piping
s Electrical power
s Location of drain for condensate
2. Check area around boiler. Remove any combustible materials,
gasoline and other flammable liquids.
Failure to keep boiler area clear and free of combustible
materials, gasoline and other flammable liquids and
vapors can result in severe personal injury, death or
substantial property damage.
3. The SlimFit boiler must be installed so that gas control system
components are protected from dripping or spraying water or rain
during operation or service.
4. If new boiler will replace existing boiler, check for and correct
system problems, such as:
s System leaks causing oxygen corrosion or heat exchanger cracks
from hard water deposits.
s Incorrectly-sized expansion tank.
s Lack of freeze protection in boiler water causing system and
boiler to freeze and leak.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes — at least ½” from combustible materials.
2. Vent pipe — at least ³⁄₁₆” from combustible materials.
3. See Figure 1 for other clearance minimums.
Clearances for service access
1. See Figure 1 for recommended service clearances. If you do not
provide minimum clearances shown, it might not be possible to
service the boiler without removing it from the space.
6
#LEARANCE
FROM
-INIMUM
CLEARANCE TO
COMBUSTIBLE
SURFACES
INCHES
2ECOMMENDED
SERVICE ACCESS
CLEARANCES
INCHES
,%&4
0
0
2)'(4
0
12
4/0
20
20
"/44/&LOOR
0
0
&2/.4
1
⁄2
24
0
0
⁄16 **
NA
⁄2
NA
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3
(/4 7!4%2
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1
Openings in combustible floors, walls, ceilings or
roofs must be 3⁄8” larger in diameter than the vent pipe
and must be lined with steel thimbles and designed for
fire stopping as required by applicable codes.
Provide air openings for combustion air and/
or ventilation of the room as specified in this
manual and as required by applicable codes.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Prepare boiler location (continued)
Flooring and foundation
Flooring
2. DIRECT EXHAUST — For direct exhaust installations (com-
1. The SlimFit boiler is approved for installation on combustible
flooring, but must never be installed on carpeting.
Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal
injury, death or substantial property damage.
Foundation
1. The boiler mounting surface must be level and suitable for
the load.
2. Provide a solid foundation pad, at least 2 inches above the
floor, if any of the following is true:
s floor can become flooded.
s the floor is dirt, sand, gravel or other loose material.
s the boiler mounting area is severely uneven or sloped.
3. The minimum foundation size is:
s 48 inches wide x 20 inches deep.
4. Foundation may be of wood, brick or concrete (minimum 2
inches thick) construction.
5. If flooding is possible, elevate boiler sufficiently to prevent
water from reaching boiler.
Garage installation
Precautions
1. Take the following special precautions when installing the
boiler in a garage. If the boiler is located in a garage:
s Mount the boiler at a height above the floor as specified
in the National Fuel Gas Code, ANSI Z223.1 for U. S.
installations, or CSA B149.1 and B149.2 for Canadian
installations.
s Locate or protect the boiler so it cannot be damaged by
a moving vehicle.
s Ensure that the installation complies with all applicable
codes.
Provide air openings to room
Air openings — General
bustion air from inside), provide air openings as specified in
the direct exhaust venting section of this manual.
Air openings — SlimFit boiler in same room
with other gas or oil-fired appliances
1. DIRECT VENT — For direct vent installations (combustion
air piped to boiler), size openings only on the basis of the
other appliances in the space. No additional air opening
free area is needed for the SlimFit boiler because it takes its
combustion air from outside.
For direct vent installations, when the SlimFit boiler
is located in the same room as other appliances,
provide combustion air openings correctly sized
for all appliances in the room except the SlimFit
boiler.
Reinstall the boiler jacket front door after servicing.
The boiler front door must be securely fastened to
the boiler to prevent the boiler from drawing air
from inside the boiler room. This is particularly
important if the boiler is located in the same room
as other appliances.
Failure to comply with the above warnings could
result in severe personal injury, death or substantial
property damage.
2. DIRECT EXHAUST — For direct exhaust installations, com-
bustion air openings into the room must be sized to handle
the SlimFit boiler and all other appliances. See the direct
exhaust venting instructions in this manual for required
openings.
For direct exhaust installations, when the SlimFit
boiler is located in the same room as other appliances, provide combustion air openings correctly
sized for all appliances, including the SlimFit boiler.
Failure to comply with the above warnings could
result in severe personal injury, death or substantial
property damage.
Follow the National Fuel Gas Code (U. S.) or CSA B149.1 and
B149.2 (Canada) and all applicable codes to size/verify size of the
combustion/ventilation air openings into the space. See the venting instructions section of this manual for required air openings
and sizing for either direct vent or direct exhaust installation.
Air openings — SlimFit boiler alone in boiler
room
1. DIRECT VENT — For direct vent installations (air piped
to boiler), no air ventilation openings into boiler room are
needed if clearances around the SlimFit boiler are at least
equal to the SERVICE clearances shown in Figure 1, page 6.
For spaces that DO NOT supply the minimum service access
clearances, see the direct vent venting instructions in this
manual for required openings.
Part number 550-100-168/0516
7
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Prepare boiler
Vent and air piping requirements (page 20)
1. The SlimFit boiler requires a special vent system, designed
for pressurized venting.
a. SlimFit boilers are rated ANSI Z21.13 Category IV (pressurized vent, likely to condense in the vent).
b. SlimFit commercial boilers can be either DIRECT EXHAUST
(vent to the outside, combustion air from inside) or
DIRECT VENT (vent and air piped outside).
c. See instructions beginning on page 20 for vent/air configuration options and installation requirements.
2. Note “Prevention of combustion air contamination” on
page 22 when considering vent/air terminations and boiler
room conditions when using inside air (direct exhaust installation).
3. Be sure to locate the boiler such that the vent and air piping
can be routed through the building and properly terminated.
The vent/air piping lengths, routing and termination method
must all comply with the methods and limits in instructions
beginning on page 21.
Remove boiler from crate
Cold weather handling — If boiler has been stored in a
very cold location (below 0°F) before installation, handle
with care until the plastic components come to room
temperature.
Do not lift or handle the boiler by the water or gas
pipes.
1. Leave boiler on crate base until ready to place in final location.
2. Cut the retaining straps. Make sure the boiler is sitting securely.
3. Remove outer shipping carton from boiler.
Leave the plastic cover on the boiler vent outlet until
ready to attach vent piping. This will prevent debris from
falling into the vent adapter.
Flue cover
Prepare boiler for propane
(when required)
3LIM&IT BOILERS MUST BE CONVERTED FOR
PROPANE OPERATION ˆ ALL BOILERS ARE
SHIPPED READY FOR NATURAL GAS OPERA
TION AND MUST BE lTTED WITH A PROPANE
ORIlCE TO BE USED ON PROPANE -ODEL
BOILERS ALSO REQUIRE INSTALLATION OF
A PROPANE BLOWER ORIlCE SUPPLIED IN
THE PROPANE CONVERSION KIT
(IGH ALTITUDE INSTALLATIONS
No orifice change is required for high-altitude
installations. The Control automatically adjusts boiler operation for altitude when set
properly. Select “9%3” in the Control setup
for the (IGH !LTITUDE option (see Figure 62,
page 73).
6ERIFY ORIlCE SIZE
See Figure 2, page 10. Verify when installing the
propane orifice that the orifice size marking
matches boiler size.
Model 750 boilers also require installation of
a blower orifice for propane operation. The
orifice is supplied in the propane conversion
kit.
#ONVERTING EXISTING NATURAL GAS lRED
BOILER FOR PROPANE
For a boiler already installed, you must turn
off gas supply, turn off power and allow boiler
to cool before proceeding.
6ERIFY OPERATION AFTER CONVERSION
You must completely test the boiler after conversion to verify performance. Start up the
boiler following instructions in this manual.
&AILURE TO COMPLY WITH THE ABOVE COULD
RESULT IN SEVERE PERSONAL INJURY DEATH OR
SUBSTANTIAL PROPERTY DAMAGE
Install propane orifice — SF-550 or -750
4. After removing the packaging, lift boiler from the skid and
place in position.
Do not drop the boiler. Damage to boiler components can result.
)NSPECT THE BOILER BASE FOR CRACKS OR POSSIBLE
DAMAGE IN HANDLING. The base must be in good
condition and sealed tightly for proper operation
of the boiler.
Placing the boiler
1. Set the boiler in place and check level. Use shims if necessary
to level the boiler (and condensate pump, if used).
8
)F BOILER IS ALREADY INSTALLED — You must turn
off electrical supply to the boiler and close the
external manual gas shut-off valve to isolate the
boiler during conversion. Allow the boiler to cool
if it has been operating. Following conversion of
an installed boiler, follow all instructions in this
manual to start up the boiler and verify operation
of the boiler and all system components.
SF-550 boilers are shipped with a blower plate that is
used for natural gas and propane. The blower plate
must be left in place for propane applications.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Prepare boiler (continued)
1. Locate propane orifice disc from conversion kit bag shipped
with the boiler.
2. Verify that the stamping on the orifice disk matches the model
size (see Figure 2, page 10).
3. Remove front door by rotating the two rotary latches.
4. Lift the door away from boiler.
5. See Figure 2, page 10.
6. Disconnect the gas train adapter flange (see item 12) from
the venturi gas line flange (see item 7):
a. Use a 4 mm Allen wrench and 8 mm open-end or box
wrench to loosen the four (4) screws and nuts (items 10
and 11).
b. Remove the gasket (item 9).
Inspect the gasket between the gas train adapter
flange (see item 12) and the venturi gas line flange
(see item 7). The gasket must be in good condition
and must be installed. Failure to comply could result in a gas leak, resulting in severe personal injury,
death or substantial property damage.
c. The gas train is connected with a flexible gas line. Pull the
gas train forward and support it temporarily.
d. Insert the propane orifice into the counterbore in the
venture flange.
e. Reposition the gasket and gas train adapter against the
venturi gas line flange.
f. Secure with the four (4) screws and nuts. Do not overtighten, but make sure the joint is secure (torque to
1.5 N-m/13 in-lbs/1 ft-lb).
SF-750 propane only — Install the
propane blower plate and gaskets
1. See Figure 2, page 10.
2. Disconnect the two wire harnesses connected to the blower.
3. SF-750 natural gas boilers do not use a blower plate. The
boiler is shipped with a blower plate and gaskets that must
be installed to operate the boiler on propane.
4. Obtain the two (2) gaskets (item 3) and blower plate (item 4)
shipped with the boiler.
5. Check the blower plate to ensure it says “750 LP.”
6. Turn off all power sources to the boiler.
7. Disconnect the two (2) wiring connectors on the blower.
8. Disconnect the blower flange (see item 6) from the mixing
tube flange (see item 5) as shown.
9. Use a 13 mm nut driver or ratchet for the screws and a 13 mm
open-end wrench for the nuts.
10. Support the weight of the blower and gas train temporarily.
11. Insert the top two (2) bolts through the mixing tube flange.
12. Slide on the two (2) gaskets and blower plate, with one gasket
on each side as shown.
13. Position the blower.
14. Align all parts and start the nuts on the top two (2) bolts.
15. Insert the remaining two (2) bolts and fasten with nuts. Be
careful not to tear the gasket.
Part number 550-100-168/0516
16. Secure the flanges together with the bolts and nuts, being
careful not to over-tighten (torque to 15 N-m/132 inlbs/11 ft-lbs).
17. Reconnect the two (2) blower wiring harnesses.
18. Reinstall front door, and secure the latches.
19. Restore electrical power, turn on gas by opening manual gas
valve and check for leaks.
20. Follow instructions starting on page 86 to adjust combustion
values for propane gas.
21. Perform a complete start up sequence, starting on page 83,
including a check for gas leaks and confirming proper performance.
22. After placing the boiler in operation, the ignition system safety
shutoff device must be tested, page 87.
Legend for Figure 2, page 10
(see Figure 98, page 116 for part numbers)
1.
2.
3.
4.
Hex bolts (4), M8 x 30 mm — requires 13 mm open-end wrench,
box wrench or ratchet.
Hex nuts (4), M8 keps — nylon lock nuts — requires 13 mm openend wrench, box wrench or ratchet.
Blower plate gasket (one on each side of blower plate). One gasket is
used on SF-750 natural gas, because this unit does not use a blower
plate — blower plate is only used for the SF-750 propane. SF-550
boilers use a plate for natural gas and propane (same plate is used
for both fuels).
Blower plate — used on all SF-550, natural gas and propane; used on
SF-750 propane only (not on SF-750 natural gas).
5.
Mixing tube.
6.
Blower motor and blower.
7.
Venturi — with gas line flange and inlet air connection.
8.
Propane orifice — shipped with boiler — verify the model number
stamped on the orifice.
9.
Gasket — venturi gas flange to gas line adapter flange.
10. Hex nuts (4), M5 keps — requires 8 mm open-end or box wrench.
11. Hex bolts (4), M 5 x 20 mm — requires 4 mm Allen wrench.
12. Gas line adapter flange.
13. Manual gas valve.
14. Automatic gas valve.
9
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Prepare boiler (continued)
&IGURE See page 9 for legend
A BLOWER PLATE is used on all SF-550 boilers, for both natural gas and propane.
A BLOWER PLATE is used on SF-750 propane, but NOT on natural gas.
A PROPANE ORIlCE MUST be installed on both the SF-550 and SF-750 to operate on propane.
"LOWER PLATE MOUNT WITH )$ STAMPING LOCATED AS SHOWN
s
s
1
3
Verify model number & fuel ˆ .',0 or ,0
Install plate with I. D. stamping toward front of boiler and facing blower
4
3
2
BACK
SIDE
6
5
7
13
0ROPANE ORIlCE
Verify model number ˆ
Heat
exchanger
,0
14
or
,0
11
12
9
10
8
10
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Prepare boiler (continued)
$/ ./4 INSTALL A RELIEF VALVE WITH A PRESSURE
HIGHER THAN 03)'. This is the maximum al-
&IGURE Hydrostatic test piping connections
lowable relief valve setting for the SlimFit boiler.
The boiler is shipped with a 30 PSIG relief valve.
See Replacement parts in the back of this manual
for alternate pressure setting relief valves.
Perform hydrostatic pressure test
Pressure test boiler before permanently attaching water or gas
piping or electrical supply.
Prepare boiler for test
1. See Figure 3 for reference in following steps. Use pipe dope
sparingly.
2. Remove 2” supply line tee, 2x¾” bushing and ¾” nipple from
accessory bag.
3. Pipe 2” tee, bushing and ¾” nipple to boiler supply connection as shown.
4. Temporarily plug the end of the 2” supply tee.
5. Attach a ¾” shut-off valve (by others) to the ¾” nipple.
6. Attach a 2-inch tee (by others) to the boiler return pipe.
7. Install a bushing and a ¾-inch boiler drain valve off of the
tee as shown. Temporarily plug the end of the tee. (All fittings by others.)
8. Connect a hose to the boiler drain valve, with the other end
connected to a fresh water supply. Make sure the hose can
also be used to drain the boiler after test.
9. To avoid getting water on the boiler, you may want to pipe
street elbows on top of shutoff valves and attach catch-buckets
beneath.
10. If convenient, install any other piping compatible with Figure 3 that would still allow bleeding air from shutoff valves.
Fill and pressure test
1. Open the shutoff valves you installed on supply and return
connections.
2. Slowly open boiler drain valve and fresh water supply to fill
boiler with water. The boiler will fill quickly because of its
low water content.
3. When water reaches the shutoff valve on top, allow water to
flow long enough to ensure all air is out of the heat exchanger.
Then close the boiler drain valve.
4. Close shutoff valve on top.
5. Increase test pressure until the pressure/temperature gauge
reaches 120 psig, but no higher. DO NOT exceed 120 psig.
6. Hold at test pressure for 10 minutes.
Do not leave boiler unattended. A cold water fill
could expand and cause excessive pressure, resulting in severe personal injury, death or substantial
property damage.
7. Make sure constant gauge pressure has been maintained
throughout test. Check for leaks. Repair if found.
Part number 550-100-168/0516
,EAKS MUST BE REPAIRED AT ONCE Failure to do so can damage boiler, resulting
in substantial property damage.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Gaskets and seals
in the system may be damaged. This can result in
substantial property damage.
Drain and remove fittings
1. Disconnect fill water hose from water source.
2. Drain boiler through drain valve. Remove hose after draining.
3. Remove pipe fittings unless they will remain for use in the
system piping.
4. Remove the ¾” shut-off valve from the ¾” relief valve nipple.
5. See page 12 to install relief valve (female)on the ¾” nipple.
11
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install water piping
Use two wrenches when tightening water piping at
boiler, using one of the wrenches to prevent the boiler
interior piping from turning. Failure to support the
boiler piping connections to prevent them from turning could cause damage to boiler components.
Install relief valve
1. Install relief valve (female) on the ¾” nipple in the
2x¾” bushing on the boiler supply piping tee (Figure 3,
page 11). The relief valve must be piped with no smaller
than ¾” pipe and fittings.
General piping information
Additional controls, when required
The Control module uses temperature sensors to
provide both high limit protection and modulating
temperature control, and is UL353 Limit Controls
certified to meet ASME CSD-1 and Section IV requirements. The Control module also provides low water
protection, both with a low water cut-off inside the
boiler jacket and by sensing the temperature of the
heat exchanger. Some codes/jurisdictions may require
additional external controls.
Additional limit controls
1. Consult local requirements for other codes/standards to determine if additional limit devices are needed.
-ULTI TEMPERATURE SYSTEMS — If the heating system includes circuits that require lower temperature
water (radiant slab circuits, for example) as well as
higher temperature circuits, it is recommended to
protect low-temperature circuits with limit controls
that are wired to a Control external limit circuit (P13
terminals 1 and 2 for manual reset, or P13 terminals 3
and 4 for automatic reset).
2. See instructions beginning on page 50 for wiring information.
a. Manual reset operation: If external limit controls are to cause
MANUAL RESET of the Control module, connect series-wired
isolated contacts to P13 terminals 1 and 2 (see page 50 for
wiring information).
b. Automatic reset operation: If external limit controls are to
cause AUTOMATIC RESET of the Control module, connect
series-wired isolated contacts to P13 terminals 3 and 4 (see
page 50 for wiring information).
Low water cutoff
1. A push-to-test low water cutoff is included with the boiler. The
low water cutoff is mounted on the boiler supply manifold, and
is available for test by removing the boiler jacket.
2. Operation of the low water cutoff is manual reset through the
Control.
Backflow preventer
1. Use backflow check valve in cold water supply as required by
local codes.
12
2. Connect discharge piping to safe disposal location, following guidelines in the 7!2.).' below.
4O AVOID WATER DAMAGE OR SCALDING
DUE TO RELIEF VALVE OPERATION AS PER
LOCAL OR STATE CODES:
Discharge line must be connected to relief valve outlet and run to a safe place
of disposal. Terminate the discharge
line in a manner that will prevent
possibility of severe burns or property
damage should the valve discharge.
Discharge line must be as short as possible and be the same size as the valve
discharge connection throughout its
entire length.
Discharge line must pitch downward
from the valve and terminate at least
6” above the floor drain where any
discharge will be clearly visible.
The discharge line shall terminate
plain, not threaded, with a material
serviceable for temperatures of 375 °F
or greater.
Do not pipe the discharge to any place
where freezing could occur.
No shutoff valve shall be installed between the relief valve and boiler, or in
the discharge line. Do not plug or place
any obstruction in the discharge line.
Test the operation of the valve after
filling and pressurizing system by
lifting the lever. Make sure the valve
discharges freely. If the valve fails to
operate correctly, replace it with a new
relief valve.
Failure to comply with the above
guidelines could result in failure of the
relief valve to operate, resulting in the
possibility of severe personal injury,
death or substantial property damage.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install water piping (continued)
System water piping methods
&IGURE All piping methods shown in this manual use PRI
Boiler head loss vs flow rate for SF-550 &
SF-750
MARYSECONDARY CONNECTION TO THE BOILER LOOP.
These designs ensure proper flow through the SlimFit
boiler, for the most efficient and reliable operation of
the boiler and the heating system. For other piping
methods, consult your local Weil-McLain representative or see separate SlimFit boiler piping guides.
Recommended pipe sizing
Connect minimum pipe sizing shown in Figure 4 to the supply and
return connections for SF-550 and SF-750 boilers.
&IGURE Suggested pipe sizing for boiler loop
Model
Boiler loop
SF-550
2” or larger
SF-750
2” or larger
Size the piping and the boiler circulator to provide the required
temperature rise through the boiler loop. See Figure 5 for the
head loss through the boiler and minimum/maximum flow rates.
$/ ./4 design the piping and components for a
boiler loop flow rate above or below the range given
in Figure 4. Insufficient flow will cause nuisance
outages due to limit operation. Excessive flow can
damage to the boiler heat exchanger from erosion.
Circulators
The boiler circulator must be supplied by others. Locate the boiler
circulator in the return piping, as shown in the appropriate piping
diagram in this manual.
$/ ./4 use the boiler circulator in any location
other than the ones shown in this manual. The
boiler circulator must be selected to ensure adequate flow through the SlimFit boiler.
Install the boiler circulator only on the boiler return
piping. This ensures the pressure drop through the
boiler will not cause low pressure in the circulator
intake.
3& GPM
3& Temp. Boiler head loss
Rise °F
Feet w.c.
GPM
Temp. Boiler head loss
Rise °F
Feet w.c.
25
41.0
6.3
30
46.4
6.3
30
34.1
8.1
35
39.8
7.6
40
34.8
9.2
40
25.6
12.5
45
22.8
15.1
50
27.8
13.0
50
20.5
18.1
55
25.3
15.3
55
18.6
21.3
60
23.2
17.9
65
21.4
20.7
70
19.9
23.6
35
DO NOT design for flow rates
above or below the range listed
above.
DO NOT design for flow rates
above or below the range listed
above.
* Suggested design flow rates (30°F temperature rise)
Failure to comply could result in unreliable performance and nuisance shutdowns from insufficient
flow.
A Taco model 1400-50 or equivalent will work for most boiler
loop circulator applications.
Part number 550-100-168/0516
13
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install water piping (continued)
Expansion tank and make-up water
&IGURE Expansion tank piping
1. Ensure expansion tank size will handle boiler and system
water volume and temperature. Allow 7 gallons per boiler
for the boiler and its piping.
Undersized expansion tanks cause system water to
be lost from relief valve and make-up water to be
added through fill valve. Eventual boiler failure can
result due to excessive make-up water addition.
2. Tank must be located as shown in this manual, or following
recognized design methods. See tank manufacturer’s instructions for details.
3. Connect the expansion tank to the air separator only if the
separator is on the suction side of the circulator. Always install
the system fill connection at the same point as the expansion
tank connection to the system.
4. Most piping drawings in this manual show diaphragm expansion tanks. See Figure 6 for piping from air separator to
expansion tank and make-up water line using a closed-type
expansion tank.
5. Most chilled water systems are piped using a closed-type tank,
as shown in Figure 11, page 19.
Diaphragm (or bladder) expansion tank
1. (Figure 6) Always install an automatic air vent on top of the
air separator to remove residual air from the system.
When using diaphragm or bladder tanks only —
when the boiler is installed above the system main
piping, install an automatic air vent in the top of
the outgoing boiler piping to prevent air pocketing.
Closed-type expansion tank
1. See Figure 6, Alternate, for piping connections when using a
closed-type expansion tank.
2. Pitch any horizontal piping up towards tank 1 inch per 5 feet
of piping. Connect to tank with at least ¾” piping to allow
room for air to rise.
DO NOT install automatic air vents on closedtype expansion tank systems. Air must remain in
the system and return to the tank to provide its air
cushion. An automatic air vent would cause air to
leave system, resulting in water-logging the expansion tank.
Install a union on the boiler supply and return
connections as close as possible to the boiler to
allow disconnection for service when required.
See Figure 6.
14
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install water piping (continued)
ZONE VALVE zoning – primary/secondary
(Shown with optional DHW piping)
&IGURE See Figure 7.
Zone valve zoning plus optional DHW
piping
This configuration is for zone valve systems using a boiler loop connected
as a secondary circuit off of a primary system loop. The primary/secondary piping shown ensures the boiler loop will have sufficient flow. It also
avoids applying the high head of the boiler circulator to the zone valves.
1. Install a system circulator (supplied by installer) capable of delivering
the proper flow and head as shown.
2. The flow/check valve shown on the boiler outlet piping prevents
gravity circulation in the boiler loop during DHW heating.
Use AT LEAST the -).)-5- pipe size shown in
Figure 4, page 13 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection, item 21).
0RIMARYSECONDARY PIPING SHOWN ensures the boiler
loop will have sufficient flow. For other piping methods,
see guides on page 13.
Expansion Tank required
1. Provide a system expansion tank following the guidelines on page 14.
2. DO NOT use a closed-type tank if connecting to a water heater that
is equipped with an automatic vent.
Domestic Hot Water (DHW) tank, if used
1. DHW direct connection—Pipe from the near-boiler piping to the
DHW tank’s boiler connections as shown.
2. DHW as zone—A DHW tank can be connected as a zone if a DHW
tank is NOT already connected to the boiler. See Advanced Manual
to configure Boiler Pump to run during DHW demands and change
TARGET MOD SENSOR to System Supply.
3. Priority of DHW/Space Heating:
a. DHW Priority – DHW is priority over space heating. Use
Priority1 for DHW; Priorities 2 and/or 3 for space heating.
The control will not run multiple priorities simultaneously.
b. Space Heating Priority – Space heating is priority over DHW.
Use Priorities 1 and/or 2 for space heating; Priority 3 for DHW.
The control will not run multiple priorities simultaneously.
c. No Priorities – Space heating and DHW can occur simultaneously. Use only if DHW is a zone in system. Assign DHW
and Space heating to same Priority. Do not use outdoor
reset for this application.
Controlling the circulators
1. The control can control up to four circulators (boiler circulator
and three others). Refer to Field wiring, beginning on page 50, for
instructions on wiring to circulators.
2. The factory default settings are: all three inputs are set up for Space
Heating (Priority 2). Each input correlates to its respective circulator output. For DHW applications, assign DHW inputs to determined
Priority (1, 2 or 3). Priority 1 is defaulted to DHW for DHW
Priority applications.
3. For more than 3-zones, use Weil-McLain WMZV zone valve
controller.
Connect zone valve end switches to a Space
Heating Priority input, (default Priority 2) to use
default settings. Connect system circulator to corresponding output.
Use isolation relays if connecting 3-wire zone
valve end switches to the inputs.
Legend — Figure 7
1
2
3
4
5
6
7
8
SlimFit boiler
Indirect water heater (DHW), if used
Boiler relief valve (see page 12 for piping details)
Relief valve discharge piping (see page 12 for details)
DHW circulator)
Isolation valves
System circulator (see information above for wiring)
Diaphragm (or bladder) type expansion tank (see page 14 for
piping of closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
Part number 550-100-168/0516
12
13
20
21
24
Boiler circulator
Zone valves, typical
Make-up water supply
Primary/secondary connection
Strap system supply and return sensors to lines as shown, at least 6 pipe
diameters (but no more than 3 feet) from boiler connection tees.
25 Systems using high-head pumps may require a bypass pressure regulator to
prevent damage to control valves.
26 Boiler drain valve, ¾” or larger
31 Install a union on the boiler supply and return connections as close as possible to the boiler to allow disconnection for service when required.
Items supplied with boiler
Items supplied by others
15
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install water piping (continued)
Zoning with zone valves — alternate
High-flow-rate/high-head-loss DHW
circuits
See Figure 8.
&IGURE Zone valve zoning plus optional DHW piping
This configuration is for applications requiring DHW circuit flow
rates higher than allowable for the boiler, or for high pressure-drop
coil-type DHW tanks, connect the piping as in Figure 8. The DHW
water only flows through the secondary circuit connection piping.
The primary/secondary piping shown ensures the boiler loop will
have sufficient flow. It also avoids applying the high head of the boiler
circulator to the zone valves.
1. Make sure to size the connection piping (Figure 8, item 23) to
handle the total flow it must handle.
2. Install a system circulator (supplied by installer) capable of delivering
the proper flow and head as shown.
3. The flow/check valve shown on the boiler outlet piping prevents
gravity circulation in the boiler loop during DHW heating.
Use AT LEAST the -).)-5- pipe size shown in
Figure 4, page 13 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection, item 21).
0RIMARYSECONDARY PIPING SHOWN ensures the boiler
loop will have sufficient flow. For other piping methods,
see guides on page 13.
Expansion Tank required
1. Provide a system expansion tank following the guidelines on page 14.
2. DO NOT use a closed-type tank if connecting to a water heater that
is equipped with an automatic vent.
Domestic Hot Water (DHW) tank, if used
1. DHW direct connection—Pipe from the near-boiler piping to the
DHW tank’s boiler connections as shown. See Advanced Manual
to configure Boiler Pump to run during DHW demands.
2. DHW as Zone – not applicable to this application.
3. Priority of DHW/Space Heating:
a. DHW Priority – DHW is priority over space heating. Use
Priority1 for DHW; Priorities 2 and/or 3 for space heating.
The control will not run multiple priorities simultaneously.
b. Space Heating Priority – Space heating is priority over DHW.
Use Priorities 1 and/or 2 for space heating; Priority 3 for DHW.
The control will not run multiple priorities simultaneously.
Controlling the circulators
2. The factory default settings are: all three inputs are set up for
Space Heating (Priority 2). Each input correlates to its respective
circulator output. For DHW applications, assign DHW inputs to
determined Priority (1, 2 or 3). Priority 1 is defaulted to DHW for
DHW Priority applications.
3. For more than 3-zones, use Weil-McLain WMZV zone valve
controller.
1. The control can control up to four circulators (boiler circulator
and three others). Refer to Field wiring, beginning on page 50, for
instructions on wiring to circulators.
Connect zone valve end switches to a Space Heating
Priority input, , (default Priority 2) to use default
settings. Connect system circulator to corresponding
output.
Use isolation relays if connecting 3-wire zone valve
end switches to the inputs.
Legend — 8
1
SlimFit boiler
Indirect water heater (DHW), if used
Boiler relief valve (see page 12 for piping details)
Relief valve discharge piping (see page 12 for details)
DHW circulator)
Isolation valves
System circulator (see information above for wiring)
Diaphragm (or bladder) type expansion tank (see page 14 for
piping of closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
2
3
4
5
6
7
8
16
12 Boiler circulator
13 Zone valves, typical
20 Make-up water supply
21 Primary/secondary connection
23 DHW secondary connector piping — no more than 8 pipe diameters apart.
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
diameters (but no more than 3 feet) from boiler connection tees.
25 Systems using high-head pumps may require a bypass pressure regulator to
prevent damage to control valves.
26 Boiler drain valve, ¾” or larger
31 Install a union on the boiler supply and return connections as close as possible to the boiler to allow disconnection for service when required.
Items supplied with boiler
Items supplied by others
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install water piping (continued)
Circulator zoning – primary/secondary
(Shown with optional DHW piping)
&IGURE See Figure 9.
Circulator zoning plus optional DHW piping
This configuration is for circulator-zoned systems using a boiler loop
connected as a secondary circuit off of a primary system loop.
1. Install a separate circulator (supplied by installer) for each zone
capable of delivering the proper flow and head as shown.
2. The flow/check valve shown on the boiler outlet piping prevents
gravity circulation in the boiler loop during DHW heating.
Use AT LEAST the -).)-5- pipe size shown in
Figure 4, page 13 on all boiler loop piping (connecting
boiler to and from the primary/secondary connection,
item 21). 0RIMARYSECONDARY PIPING SHOWN ensures
the boiler loop will have sufficient flow. For other piping
methods, see guides on page 13.
Expansion Tank required
1. Provide a system expansion tank following the guidelines on
page 14.
2. DO NOT use a closed-type tank if connecting to a water heater
that is equipped with an automatic vent.
Domestic Hot Water (DHW) tank, if used
1. DHW direct connection—Pipe from the near-boiler piping to the
DHW tank’s boiler connections as shown.
2. DHW as zone—A DHW tank can be connected as a zone if a DHW
tank is NOT already connected to the boiler. See Advanced Manual
to configure Boiler Circulator to run during DHW demands and
change TARGET MOD SENSOR to System Supply.
3. Priority of DHW/Space Heating:
a. DHW Priority – DHW is priority over space heating. Use Priority1 for DHW; Priorities 2 and/or 3 for space heating. The control
will not run multiple priorities simultaneously.
b. Space Heating Priority – Space heating is priority over DHW. Use
Priorities 1 and/or 2 for space heating; Priority 3 for DHW. The
control will not run multiple priorities simultaneously.
c. No Priorities – Space heating and DHW can occur simultaneously. Use only if DHW is a zone in system. Assign DHW and
Space heating to same Priority. Do not use outdoor reset for
this application.
Controlling the circulators
1. The control can control up to four circulators (boiler circulator
and three others). Refer to Field wiring, beginning on page 50, for
instructions on wiring to circulators. The boiler circulator cannot
be used for a zone pump.
2. The factory default settings are: all three inputs are set up
for Space Heating (Priority 2). Each input correlates to its
respective circulator output. For DHW applications, assign
DHW inputs to determined Priority (1, 2 or 3). Priority 1 is
defaulted to DHW for DHW Priority applications.
3. For more than 3-zones, use Weil-McLain WMCR zone Circ
controller.
Legend — 9
1
SlimFit boiler
Indirect water heater (DHW), if used
Boiler relief valve (see page 12 for piping details)
Relief valve discharge piping (see page 12 for details)
DHW circulator)
Isolation valves
System circulator (see information above for wiring)
Diaphragm (or bladder) type expansion tank (see page 14 for
piping of closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
2
3
4
5
6
7
8
Part number 550-100-168/0516
12 Boiler circulator
13 Zone valves, typical
14 Zone circulators, typical
20 Make-up water supply
21 Primary/secondary connection
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
diameters (but no more than 3 feet) from boiler connection tees.
26 Boiler drain valve, ¾” or larger
31 Install a union on the boiler supply and return connections as close as possible to the boiler to allow disconnection for service when required.
Items supplied with boiler
Items supplied by others
17
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install water piping (continued)
Radiant Heating — Zone valve zoning – primary/ &IGURE secondary (Shown with optional DHW piping)
See Figure 10.
Typical radiant heating system piping plus
optional DHW
The SlimFit boiler is ideal for use in radiant heating. The unique heat
exchanger design allows it to work well even in condensing mode. There
is no need to regulate boiler return water temperature in radiant heating
applications. The primary/secondary piping shown ensures the boiler loop
will have sufficient flow. It also avoids applying the high head of the boiler
circulator to the zone valves.
1. Apply this configuration for typical radiant heating applications.
2. Size the system piping and circulators to provide the flow and pressure
drop needed.
3. The flow/check valve shown on the boiler outlet piping prevents gravity
circulation in the boiler loop during DHW heating.
Use A T L E A S T the - ) . ) - 5 - pipe size show n in
Figure 4, page 13 on all boiler loop piping (connecting boiler
to and from the primary/secondary connection, item 21).
0RIMARYSECONDARY PIPING SHOWN ensures the boiler loop
will have sufficient flow. For other piping methods, see guides
on page 13.
High limit in system piping
1. Add the recommended high limit control (Figure 10, item 22) to help ensure
supply water temperature will not exceed the maximum allowable for the
radiant system.
2. Wire the limit control to either the manual reset or automatic reset external
limit circuit of the Control.
Expansion Tank required
1. Provide a system expansion tank following the guidelines on page 14.
2. DO NOT use a closed-type tank if connecting to a water heater that is
equipped with an automatic vent.
Domestic Hot Water (DHW) tank, if used
1. DHW direct connection—Pipe from the near-boiler piping to the DHW
tank’s boiler connections as shown.
2. DHW as zone— Not recommended for this application.
3. Priority of DHW/Space Heating:
a. DHW Priority – DHW is priority over space heating. Use Priority
1 for DHW; Priorities 2 and/or 3 for space heating. The control will
not run multiple priorities simultaneously.
b. Space Heating Priority – Space heating is priority over DHW. Use
Priorities 1 and/or 2 for space heating; Priority 3 for DHW. The
control will not run for DHW. The control will not run multiple
priorities simultaneously.
Controlling the circulators
1. The control can control up to four circulators (boiler circulator and
three others). Refer to Field wiring, beginning on page 50, for instructions on wiring to circulators.
2. The factory default settings are: all three inputs are set up
for Space Heating (Priority 2). Each input correlates to its
respective circulator output. For DHW applications, assign
DHW Input(s) to determined Priority (1, 2, or 3). Priority
1 is defaulted to DHW for DHW Priority applications.
3. For more than 3-zones, use Weil-McLain WMCR zone Circ
controller.
Connect zone valve end switches to a Space
Heating Priority input, (default Priority 2) to
use default settings Connect system circulator
to corresponding output.
Use isolation relays if connecting 3-wire zone
valve end switches to the inputs.
Legend — 10
1
SlimFit boiler
2 Indirect water heater (DHW), if used
3 Boiler relief valve (see page 12 for piping details)
4 Relief valve discharge piping (see page 12 for details)
5 DHW circulator
6 Isolation valves
7 System circulator (see information above for wiring)
8 Diaphragm (or bladder) type expansion tank (see page 14 for piping of
closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
10 Flow/check valves
11 Purge/drain valves
12 Boiler circulator
18
13 Zone valves, when used (zoning may also be done using manifold-mounted valve
actuators)
20 Make-up water supply
21 Primary/secondary connection (tees no more than 8 pipe diameters apart)
22 Optional high limit temperature control, set to protect radiant tubing
24 Strap system supply and return sensors to lines as shown, at least 6 pipe
diameters (but no more than 3 feet) from boiler connection tees.
25 Systems using high-head pumps may require a bypass pressure regulator to
prevent damage to control valves.
26 Boiler drain valve, ¾” or larger
31 Install a union on the boiler supply and return connections as close as possible to the boiler to allow disconnection for service when required.
Items supplied with boiler
Items supplied by others
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install water piping (continued)
WATER CHILLER systems — ZONE VALVES
primary/secondary See Figure 11.
&IGURE Chilled water system plus optional DHW
piping
1. The chiller must be piped in parallel with the boiler.
2. Use appropriate valves to prevent chilled medium from entering boiler.
3. Circulator zoning option — The space heating system can be zoned with
circulators if a separate circulator is supplied for the chilled water loop.
Install a separate circulator for each zone.
4. The flow/check valve shown on the boiler outlet piping prevents gravity
circulation in the boiler loop during DHW heating.
Use A T L E A S T the - ) . ) - 5 - pipe size show n in
Figure 4, page 13 on all boiler loop piping (connecting boiler to
and from the primary/secondary connection, item 21). 0RIMARY
SECONDARY PIPING SHOWN ensures the boiler loop will have
sufficient flow. For other piping methods, see guides on page 13.
If antifreeze is used in the system, consider the effects of antifreeze on circulator sizing and DHW performance. Some local
codes may require double-wall DHW heat exchanger design.
Use only the antifreeze listed by Weil-McLain for use with this
boiler. See page 109 for details.
Chilled medium, if used, is piped in parallel with heating boiler
as shown in Figure 11. Use appropriate valves to prevent chilled
medium from entering boiler. If boiler is connected to heating
coils located in air handling units where they can be exposed
to refrigerated air, use flow control valves or other automatic
means to prevent gravity circulation during cooling cycle.
Expansion Tank required
1. Provide a system expansion tank following the guidelines on page 14.
2. DO NOT use a closed-type tank if connecting to a water heater that is
equipped with an automatic vent.
Domestic Hot Water (DHW) tank, if used
1. DHW direct connection—Pipe from the near-boiler piping to the DHW
tank’s boiler connections as shown.
2. DHW as zone— Not recommended for this application.
3. Priority of DHW/Space Heating:
a. DHW Priority – DHW is priority over space heating. Use Priority
1 for DHW; Priorities 2 and/or 3 for space heating. The control will
not run multiple priorities simultaneously.
b. Space Heating Priority – Space heating is priority over DHW. Use
Priorities 1 and/or 2 for space heating; Priority 3 for DHW. The
control will not run multiple priorities simultaneously.
Controlling the circulators
Priority (1, 2, or 3). Priority 1 is defaulted to DHW for DHW
Priority applications.
3. For more than 3-zones, use Weil-McLain WMZV zone valve
controller.
1. The control can control up to four circulators (boiler circulator and
three others). Refer to Field wiring, beginning on page 50, for instructions on wiring to circulators.
2. The factory default settings are: all three inputs are setup for Space
Heating (Priority 2). Each input correlates to its respective circulator
output. For DHW applications, assign DHW Input(s) to determined
Connect zone valve end switches to a Space Heating Priority input, (default Priority 2) to use default settings
Connect system circulator to corresponding output.
Use isolation relays if connecting 3-wire zone valve
end switches to the inputs.
Legend — 11
1
2
3
4
5
6
7
8
9
10
11
12
13
15
SlimFit boiler
Indirect water heater (DHW), if used
Boiler relief valve (see page 12 for piping details)
Relief valve discharge piping (see page 12 for details)
DHW circulator
Isolation valves
System circulator (see information above for wiring)
Diaphragm (or bladder) type expansion tank (see page 14 for piping of
closed-type expansion tank, if used)
Air separator [with automatic air vent only on systems using diaphragm
(or bladder) type expansion tank]
Flow/check valves
Purge/drain valves
Boiler circulator
Zone valves, typical
Closed-type expansion tank
Part number 550-100-168/0516
16
17
18
19
20
21
24
Water chiller
Check valve
Strainer
Balancing valve
Make-up water supply
Primary/secondary connection (tees no more than 8 pipe diameters apart)
Strap system supply and return sensors to lines as shown, at least 6 pipe
diameters (but no more than 3 feet) from boiler connection tees.
25 Systems using high-head pumps may require a bypass pressure regulator to
prevent damage to control valves.
26 Boiler drain valve, ¾” or larger
31 Install a union on the boiler supply and return connections as close as possible to the boiler to allow disconnection for service when required.
Items supplied with boiler
Items supplied by others
19
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
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 in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7) feet
above finished grade in the area of the venting, including but
not limited to decks and porches, the following requirements
shall be satisfied:
1. ).34!,,!4)/. /& #!2"/. -/./8)$% $%4%#
4/23. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or
gas fitter shall observe that a hard wired carbon monoxide
detector with an alarm and battery back-up is installed on
the floor level where the gas equipment is to be installed.
In addition, the installing plumber or gas fitter shall
observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served
by the side wall horizontal vented gas fueled equipment.
It shall be the responsibility of the property owner to
secure the services of qualified licensed professionals for
the installation of hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an
attic, the hard wired carbon monoxide detector with
alarm and battery back-up may be installed on the
next adjacent floor level.
b. In the event that the requirements of this subdivision
can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days
to comply with the above requirements; provided,
however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an
alarm shall be installed.
2. !002/6%$ #!2"/. -/./8)$% $%4%#4/23. Each
carbon monoxide detector as required in accordance with
the above provisions shall comply with NFPA 720 and be
ANSI/UL 2034 listed and IAS certified.
3. 3)'.!'%. A metal or plastic identification plate shall
be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade
directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print size no less than
one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
20
4. ).30%#4)/.. The state or local gas inspector of the
side wall horizontally vented gas fueled equipment shall
not approve the installation unless, upon inspection,
the inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions of
248 CMR 5.08(2)(a) 1 through 4.
(b) %8%-04)/.3: The following equipment is exempt from
248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment
Not Required To Be Vented” in the most current edition
of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from
the dwelling, building or structure used in whole or in
part for residential purposes.
(c) -!.5&!#452%2 2%15)2%-%.43 ˆ '!3 %15)0-%.4
6%.4).' 3934%- 02/6)$%$. When the manufacturer of
Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system
components with the equipment, the instructions provided
by the manufacturer for installation of the equipment and
the venting system shall include:
1. Detailed instructions for the installation of the venting
system design or the venting system components; and
2. A complete parts list for the venting system design or
venting system.
(d) -!.5&!#452%2 2%15)2%-%.43 ˆ '!3 %15)0-%.4
6%.4).' 3934%- ./4 02/6)$%$. When the manufacturer of a Product Approved side wall horizontally vented gas
fueled equipment does not provide the parts for venting the
flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall
be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved
by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved
side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance
or equipment at the completion of the installation.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Venting/combustion air — general
Vent and air piping materials
1. See Figure 13, page 23 for approved vent and air piping materials, for both DIRECT EXHAUST and DIRECT VENT.
5SE THE SAME VENT OR AIR PIPING MATERIAL THROUGHOUT — Do not connect different types of piping together.
3TAINLESS STEEL PIPE — Install Dura-Vent – FasNSeal™ adapter at each boiler fitting where stainless steel pipe will be
connected. Adapter is available from Dura-Vent or Weil-McLain (see page 109 for part number).
Vent piping
1. Boiler flue gases must be piped from the boiler to outside, following the instructions in this manual, and compliant with all applicable codes. The vent pipe must terminate either through the sidewall or through the roof, located with the correct separation
from the air termination. See the associated instructions in the following pages.
2. Each SlimFit boiler requires a separate vent. $/ ./4 common vent.
DIRECT EXHAUST OPTIONS
SIDEWALL
VERTICAL
Combustion air openings for direct
exhaust
1. Combustion air must be supplied through openings into the boiler
room, following the instructions in this manual, and compliant
with all applicable codes. Read the warning in Figure 12, page 22,
and ensure the air and boiler room will not contain contaminated
air.
2. Where the SlimFit boiler shares a space with other appliances, the
combustion air openings must be sized to handle the combined
requirements of all appliances in the space.
SIDEWALL direct exhaust option
s
2EAD PAGE THROUGH PAGE 4HEN GO TO PAGE VERTICAL direct exhaust option
s
2EAD PAGE THROUGH PAGE 4HEN GO TO PAGE DIRECT VENT OPTIONS
Combustion air piping for direct vent
SIDEWALL
VERTICAL
1. Combustion air must be piped from outside to the boiler, following the instructions in this manual, and compliant with all
applicable codes. Read the warning in Figure 12, page 22, and
ensure the air intake will not be likely to draw in contaminated air.
2. Combustion air can be piped individually for each boiler, or it
can be manifolded as shown in Figure 26, page 36. Combustion/
ventilation openings may also be required in boiler room walls,
per instructions in this manual and applicable codes.
SIDEWALL direct vent option
s
2EAD PAGE PAGE AND PAGE 4HEN GO TO PAGE VERTICAL direct vent option
s
Part number 550-100-168/0516
2EAD PAGE PAGE AND PAGE 4HEN GO TO PAGE 21
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
Venting/combustion air — general
3LIM&IT "OILERS MUST BE VENTED AND SUPPLIED WITH
COMBUSTION AND VENTILATION AIR USING PIPING AND
METHODS DESCRIBED IN THIS MANUAL.
DO NOT COMMON VENT
%VERY BOILER MUST HAVE ITS OWN VENT. $/ ./4
common vent with any other appliance. See page 23 for
checking appliances remaining on a common vent.
INSPECT VENT/AIR COMPONENTS
Inspect finished vent and air piping thoroughly to ensure
all are airtight and comply with the instructions provided
and with all requirements of applicable codes. Verify all
air openings are correctly sized, unobstructed, and free
of airborne contaminants.
Failure to provide a properly-installed vent and air system
will cause severe personal injury or death.
— Boiler Manual
(continued)
Combustion air contamination
1. $IRECT EXHAUST (combustion air from boiler
room):
a. Provide combustion air openings to boiler
room as described in this manual.
b. Ensure the boiler room and combustion air
source areas are free of contaminants.
2. $IRECT VENT (piped combustion air):
a. Install air inlet piping for the SlimFit boiler as
described in this manual.
b. Do not terminate air piping in locations that
can allow contamination of combustion air.
3. See Figure 12 for products and areas which may
cause contaminated combustion air.
&IGURE Corrosive contaminants and sources
Products to avoid
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Code compliance
Installations must comply with local requirements and
with the National Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 or B149.2 for Canadian
installations.
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Vent and air piping materials
Use only the materials listed in this manual (Figure 13,
page 23) for vent and air pipe and fittings.
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning
solvents found in household laundry rooms
A masonry chimney can ONLY be used as a
chase for vent and air piping
Adhesives used to fasten building products and other
similar products
)F USED A MASONRY CHIMNEY CAN /.,9 BE USED AS A
0)0% #(!3% FOR VENT AND AIR PIPES — The vent and
Excessive dust and dirt
air piping must be installed as instructed in this manual
and all joints must be sealed. The chimney must be used
only as a chase for the SlimFit boiler vent/air piping. NO
OTHER appliance or fireplace can be connected to the
chimney.
Areas likely to have contaminants
The chimney must be straight, with no offsets, and the
vent and air piping materials must comply with this
instruction manual.
The chimney must be fitted with a sealed access opening, through which the interior of the chimney can be
inspected.
The chimney and liner must be inspected at least once
annually to verify condition.
Failure to comply could result in severe personal injury,
death or substantial property damage.
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
22
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Venting/combustion air — options #ATEGORY )) )6
&IGURE Use only the materials listed below, ensuring that all materials meet local codes
3TANDARDS FOR INSTALLATIONS IN
3UPPLIER-ANUFACTURER
)TEM-ATERIAL
5NITED 3TATES
#ANADA
3EE 7!2.).' BELOW
6ENT OR AIR PIPING
Duravent / M&G – Polypro
0OLYPROPYLENE
Centrotherm Eco Systems – InnoFlue® Single-wall
6ENT OR AIR PIPE
lTTINGS
Certified for Category IV and direct vent
direct vent appliance venting.
appliance venting.
Certified for Category IV and
Certified for Category IV and direct vent
direct vent appliance venting.
appliance venting.
ANSI/ASTM D1785
ULC S636
PVC-DWV schedule 40
ANSI/ASTM D2665
NA
CPVC schedule 40
ANSI/ASTM F441
ULC S636
PVC
ANSI/ASTM D2564/F656
ULC S636
CPVC
ANSI/ASTM F493
ULC S636
Dura-Vent – FasNSeal™
!IR PIPING
Certified for Category IV and
PVC schedule 40
06# !"3 PIPE
CEMENT PRIMER
!, #
STAINLESS STEEL
6ENT PIPING
PVC, PVC-DWV,
CPVC
Use only cement
and primer
suitable for piping
material used.
Certified for Category IV and
Certified for Category IV and direct vent
direct vent appliance venting.
appliance venting.
3TAINLESS STEEL PIPE — Install Dura-Vent – FasNSeal™ adapter at each boiler fitting where stainless steel pipe will
be connected. Adapter is available from Dura-Vent or Weil-McLain (see page 109 for part number).
Appliances remaining on an existing vent system
Do not install the SlimFit boiler into a common vent with any other appliance. This
will cause flue gas spillage or appliance malfunction, resulting in possible severe
personal injury, death or substantial property damage.
Existing common vent systems may be too large for the appliances remaining connected after the existing boiler is removed.
Failure to follow all instructions can result in flue gas spillage and carbon monoxide
emissions, causing severe personal injury or death.
When removing a boiler from an
existing common vent system
4HE 3LIM&IT BOILER CANNOT BE COMMON
VENTED WITH ANY OTHER APPLIANCE. When
an existing boiler is replaced with an SlimFit
boiler, the SlimFit boiler CANNOT use the
existing common vent. The SlimFit boiler requires its own vent and air piping, as specified
in this manual. This may cause a problem for
the appliances that remain on the old common
vent, because the vent may be too large. The
following test is intended to check for proper
operation of the appliances remaining on the
old common vent system.
Vent system verification
At the time of removal of an existing boiler,
the following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the
Part number 550-100-168/0516
other appliances remaining connected to the
common venting system are not in operation.
Seal any unused openings in the common venting system.
Existing vent test procedure
(The following is intended to test
whether the appliances remaining on
an existing vent system will operate
satisfactorily.)
1. Visually inspect the venting system for
proper size and horizontal pitch and determine there is no blockage or restriction,
leakage, corrosion or other deficiencies
which could cause an unsafe condition.
2. Test vent system — Insofar as is practical,
close all building doors and windows and all
doors between the space in which the appliances remaining connected to the common
venting system are located and other spaces
3.
4.
5.
6.
of the building. Turn on clothes dryers and
any appliance not connected to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom
exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust
fan. Close fireplace dampers.
Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
Test for spillage at draft hood relief opening
after 5 minutes of main burner operation.
Use the flame of a match or candle, or
smoke from a cigarette, cigar, or pipe.
After it has been determined that each appliance remaining connected to the common venting system properly vents when
tested as outlined herein, return doors,
windows, exhaust fans, fireplace dampers,
and any other gas-burning appliance to
their previous conditions of use.
Any improper operation of common
venting system should be corrected so the
installation conforms with the National
Fuel Gas Code, ANSI Z223.1 — latest edition. Correct by re-sizing to approach the
minimum size as determined using the
appropriate tables in Part 13 of that code.
Canadian installations must comply with
B149.1 or B149.2 Installation Code.
23
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Venting/combustion air — options #ATEGORY ))
Category II Requirements
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EVDFSJTCFUXFFOUIFSBOHFTQSPWJEFEJOUIF5BCMF CFMPX EVSJOHBMMSVOOJOH CVSOFSMJU DPOEJUJPOT JF )JHI'JSF
UISPVHI-PX'JSF r'MVFHBTUFNQFSBUVSFTIPVMEOPUFYDFFEž' UIFCPJMFS
XJMMTIVUEPXOBOESFDZDMFJGJUEPFTĉFĚVFHBTUFNQFSBUVSFTIPVMEUZQJDBMMZCFXJUIJOž'PGUIFSFUVSOXBUFS
UFNQFSBUVSFPGUIFCPJMFS*GUIFSFJTUIFQPUFOUJBMGPSBXJEF
WBSJBUJPOJOSFUVSOXBUFSUFNQFSBUVSFT UIFMPXFTUQPTTJCMF
UFNQFSBUVSFTIPVMECFVTFEGPSBOZDBMDVMBUJPOT
r 4UBDL7FOU'MPX3BUFGPSFBDIJOEJWJEVBMCPJMFSNPEFMJT
MJTUFEJOUIFUBCMFCFMPXĉJTĚPXSBUFJTCBTFEPOUIFVOJU
SVOOJOHBU$0BOEUIFNBYJNVNĚVFHBTUFNQFSBUVSFPGž'ĉFWBMVFTDBOWBSZEFQFOEJOHPOUIFMPDBUJPOPGUIFJOTUBMMBUJPOBOEPQFSBUJOHDPOEJUJPOT
r " DBSCPO NPOPYJEF EFUFDUPS T JT SFRVJSFE JO UIF CPJMFS
SPPNGPS4MJN'JUCPJMFSTJOTUBMMFEJOB$BUFHPSZ**DPOėHVSBUJPO ĉF DBSCPO NPOPYJEF EFUFDUPS NVTU CF XJSFE PO
UIFTBNFFMFDUSJDBMDJSDVJUBTUIFCPJMFS$IFDLZPVSMPDBM
DPEFTGPSBOZBEEJUJPOBMSFRVJSFNFOUTPGDBSCPONPOPYJEFEFUFDUPST
Table 1 Rating and Vent Data for Category II boilers
Boiler
Model
SF-550
SF-750
Note 1:
Input
Stack / Vent
Btuh
scfm
550,000
750,000
128
175
Negative Pressure to be
maintained at
Vent Connection of the boiler
-0.001 to -0.100
-0.001 to -0.100
SlimFit Vent
Adapter required for
Category II
(See Note 1)
6-8”
6-8”
8 to 6” bell adapters are required for Category II venting.
*NQSPQFS*OTUBMMBUJPOPGB$BUFHPSZ**WFOUTZTUFNSFTVMUJOHJOQPTJUJWFQSFTTVSFJOUIFWFOUTZTUFNDBOSFTVMUJO
ĚVFHBTTQJMMBHFBOEDBSCPONPOPYJEFFNJTTJPOT DBVTJOHTFWFSFQFSTPOBMJOKVSZPSEFBUI
8FJM.D-BJOSFDPNNFOETUIFVTFPGB7BSJBCMF4QFFE$IJNOFZ'BO1PXFSWFOUFSUPFOTVSFUIBUUIFBQQSPQSJBUF
OFHBUJWFQSFTTVSFJTNBJOUBJOFEGPS$BUFHPSZ**WFOUJOHĉJTJTSFDPNNFOEFECFDBVTF BTBSFTVMUPGUIFCPJMFST
FđDJFODZ UIFFYIBVTUHBTUFNQFSBUVSFTDBOCFRVJUFMPXSFTVMUJOHJOMFTTOBUVSBMESBě"ĚPXQSPWJOHTXJUDI
TIPVMECFXJSFEJOUPUIF1SPPGPG$MPTVSFKVNQFSDJSDVJUPOUIFCPJMFSDPOUSPM4FFUIFCPJMFSNBOVBMGPSBEEJUJPOBMJOGPSNBUJPOĉFVTFPGUIJTEFWJDFTIPVMECFDPOTJEFSFEJOBOZ&OHJOFFSFE7FOUTZTUFN
8FJM.D-BJOSFDPNNFOETUIFVTFPGB%PVCMF"DUJOH#BSPNFUSJD%BNQFSPS.PEVMBUJOH%BNQFSUPFOTVSFUIF
BQQSPQSJBUFOFHBUJWFQSFTTVSFSBOHFJTLFQUGPS$BUFHPSZ**WFOUJOHĉFVTFPGUIJTEFWJDFTIPVMECFDPOTJEFSFEJO
BOZ&OHJOFFSFE7FOUTZTUFN
8IFOVTJOHBEBNQFSPGBOZLJOE JUJTSFDPNNFOEFEUPVTFBUIFSNBMTQJMMTXJUDIUPEFUFDUBOZFYIBVTUĚPXJOUP
UIFCPJMFSSPPN7FSJGZUIFUFNQFSBUVSFSBOHFPOUIFUIFSNBMTQJMMTXJUDIJTBEFRVBUFGPSUIF'MVFHBTUFNQFSBUVSF
GSPNUIFSlimFitCPJMFSĉFVTFBOETFUQPJOUPGUIJTTIBMMCFEFUFSNJOFECZUIFTZTUFNEFTJHOFSĉF"VUPSFTFU
JOQVUPOUIF#PJMFSTDPOUSPMDBOCFVTFEUPXJSFJOUIFUIFSNBMTQJMMTXJUDI
*ODSFBTJOHUIFOFHBUJWFQSFTTVSFJOUIFWFOUQJQFXJMMTMJHIUMZJODSFBTFUIFėSJOHSBUFBUMPXėSF UIVTSFEVDJOHUIF
CPJMFSTUSVFNPEVMBUJPOSBOHF$POTJEFSUIJTGBDUPSEVSJOHTZTUFNEFTJHO
Code Compliance
7FOUJOH$PNCVTUJPOBJSQJQJOHm*OTUBMMBUJPOTNVTUQSPWJEFQSPWJTJPOTGPSDPNCVTUJPOBOEWFOUJMBUJPOBJSJO
BDDPSEBODFXJUIUIFTFDUJPOi7FOUJOHPG&RVJQNFOUu PGUIF/BUJPOBM'VFM(BT$PEF "/4*;/'1" PSi7FOUJOH4ZTUFNTBOE"JS4VQQMZGPSBQQMJBODFTuPGUIF/BUVSBM(BTBOE1SPQBOF*OTUBMMBUJPO$PEF $"/
$4"# PSBQQMJDBCMFQSPWJTJPOTPGUIFMPDBMCVJMEJOHDPEFT
24
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Direct Exhaust #ATEGORY )) /NLY 6ENTING n GENERAL
3LIM&IT "OILERS MUST BE VENTED AND SUPPLIED
WITH COMBUSTION AND VENTILATION AIR USING
PIPING AND METHODS DESCRIBED
Inspect finished vent and air piping thoroughly
to ensure all are water-tight and comply with the
instructions provided and with all requirements
of applicable codes.
Failure to provide a properly-installed vent and
air system will cause severe personal injury or
death.
If the vent/air piping configurations covered in
the SlimFit boiler manual cannot be applied for
a particular installation, contact Weil-McLain for
assistance. Other configurations may be available.
Installations must comply with local requirements and with the National Fuel Gas Code,
ANSI Z223.1 for U.S. installations or CSA B149.1
or B149.2 for Canadian installations.
Use only the materials listed in the Boiler manual
for vent and air pipe and fittings. Failure to comply could result in severe personal injury, death
or substantial property damage.
)F USED A MASONRY CHIMNEY CAN /.,9 BE
USED AS A 0)0% #(!3% FOR VENT PIPE — The
vent piping must be installed as instructed in this
manual and all joints must be sealed. The chimney must be used only for boilers. NO OTHER
appliance or fireplace can be connected to the
chimney.
The chimney must be straight, with no offsets,
and the vent and air piping materials must comply with this instruction manual. The chimney
must be fitted with a sealed access opening,
through which the interior of the chimney can
be inspected. The chimney (and liner, if installed)
must be inspected at least once annually to verify
condition.
Vent piping
Boiler flue gases must be piped from the boiler to outside,
following the instructions in the Boiler manual, and
compliant with all applicable codes.
Combustion and ventilation air
openings
(direct exhaust installations)
Combustion and ventilation air are provided from the
boiler room on direct exhaust installations. Follow all
instructions in the Boiler manual, plus all applicable
codes, to provide required air openings.
Vent termination options
Vent piping must terminate out through the roof of the
building, using only one of the methods described in the
Boiler manual.
Vent pipe diameter
A 6” or 8” vent pipe diameter must be used.
Vent pipe minimum length
Direct exhaust — no minimum.
Vent and air piping materials
See the SlimFit Boiler Manual for approved vent and air
piping materials, for DIRECT EXHAUST.
5SE THE SAME VENT OR AIR PIPING MATERIAL
THROUGHOUT — Do not connect different
types of piping together.
Install a bird screen in each vent pipe termination (coupling
or elbow). Bird screens are not supplied with the SlimFit
boiler. Purchase separately from Weil-McLain.
Failure to comply could result in severe personal
injury, death or substantial property damage.
Part number 550-100-168/0516
25
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Direct Exhaust #ATEGORY )) /NLY "OILER ROOM AIR OPENING
Combustion air openings for direct
exhaust
0ROVIDE COMBUSTION AIR OPENINGS TO BOILER
ROOM AND BUILDING Combustion and ventilation
air for direct exhaust boilers is provided from the
boiler room. Follow all instructions in the Boiler
manual plus all applicable codes, providing combustion air openings as specified. Failure to comply
could result in severe personal injury, death or
substantial property damage.
1. Combustion air must be supplied through openings into the
boiler room, following the instructions in this manual and
compliant with all applicable codes. Read the warning in
Figure 12, page 22, and ensure the air and boiler room will
not contain contaminated air.
2. Where the boiler shares a space with other appliances, the
combustion air openings must be sized to handle the combined requirements of all appliances in the space.
Sizing combustion air openings
Air openings provide for ventilation (as well as combustion air)
to prevent overheating of the boiler controls and boiler space.
Air is also needed for other appliances located in the same space.
Use Figure 2, page 6, selecting the appropriate installation conditions.
Air openings must be sized to handle all appliances
and air movers (exhaust fans, etc.) using the air
supply.
The sizing given in Figure 2, page 6, is based on the National
Fuel Gas Code, ANSI Z223.1, allowing adequate air openings for
gravity-vented gas appliances (Category I) in addition to that
needed for the SlimFit boiler.
The air openings recommended in Figure 2, page 6, will allow
adequate ventilation and combustion air provided the boiler room
is not subjected to negative pressure due to exhaust fans or other
mechanical ventilation devices.
Refer to the National Fuel Gas Code for dealing with other conditions.
3. Caulking or sealants are applied to areas such as joints around
windows and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations
for plumbing, electrical, and gas lines, and in other openings.
For buildings with such construction, provide air openings into
the building from outside, sized per the appropriate case in Figure 2, page 6, if appliances are to use inside air for combustion
and ventilation.
Exhaust fans and air movers
The appliance space must never be under a negative pressure
unless all appliances are installed as direct vent. Always provide
air openings sized not only to the dimensions required for the
firing rate of all appliances, but also to handle the air movement
rate of the exhaust fans or air movers using air from the building or space.
Motorized air dampers
If the air openings are fitted with motorized dampers, electrically
interlock the damper to:
s
Prevent the boiler from firing if the damper is not fully open.
s
Shut the boiler down should the damper close during boiler
operation.
The SlimFit control provides a Proof of Closure function which
will prevent the boiler from firing if the damper is not fully
open or closes during boiler operation. Please refer to the Boiler
Manual for installation and wiring instructions.
Free area — louver allowance
The free area of openings means the area after reduction for any
installed louvers or grilles. Be sure to consider this reduction
when sizing the air openings.
Special considerations
Tight construction
ANSI Z223.1 defines unusually tight construction where:
1. Walls and ceilings exposed to the outside atmosphere have a
continuous water vapor retarder with a rating of 1 perm or
less with openings gasketed, and . . .
2. Weather-stripping has been added on openable windows and
doors, and . . .
26
Every vent pipe requires a BIRD SCREEN AT ITS
TERMINATION. Bird screens are not supplied with
the SlimFit boiler. Purchase separately from WeilMcLain.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Direct Exhaust #ATEGORY )) /NLY n 6ERTICAL
&IGURE DIRECT EXHAUST vertical termination
DIRECT EXHAUST — Vertical termination
— installation sequence overview
3TEP 3TEP s
s
Finish by attaching external pipe and fittings as shown in the
termination instructions.
s
Install terminations as described in this manual.
s
Support vertical runs on the outside of the building with
brackets as shown in the termination instructions.
3TEP s
s
s
3TEP Install the boiler.
Determine the proper location for wall penetration for each
termination.
Prepare roof penetrations before installing vent piping.
Install vent piping from boiler to termination.
Install a hanger support within 6 inches of any upturn in
the piping.
Install pipe supports every 5 feet on both the horizontal and
vertical runs.
Slope horizontal piping downward toward the boiler at least
1/4 inch per foot.
Connect the vent piping at the boiler per manual instructions.
Part number 550-100-168/0516
Determine location for vertical
termination
1. Locate the vent termination using the following guidelines:
2. The vent piping must terminate in a coupling as shown
in Figure 15, page 28.
3. Consider the surroundings when terminating the vent:
a. Position the vent termination where vapors will not
damage nearby shrubs, plants or air conditioning
equipment or be objectionable.
b. The flue products will form a noticeable plume as
they condense in cold air. Avoid areas where the
plume could obstruct window views.
c. Prevailing winds could cause freezing of condensate
and water/ice buildup where flue products impinge
on building surfaces or plants.
d. Avoid possibility of accidental contact of flue products with people or pets.
e. Do not locate the termination where wind eddies
could affect performance or cause recirculation,
such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves,
courtyards or other recessed areas.
f. Locate or guard vent to prevent condensate damage
to exterior finishes.
4. Maintain clearances as shown in the illustrations in this
manual section. Also maintain the following:
a. Vent must terminate:
s At least 12 inches above roof or snow line as
shown in Figure 15, page 28.
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At lease 3 feet above any forced air intake within
10 feet.
s No closer than 48 inches below or horizontally
from any door or window or any other gravity
air inlet.
b. Do not terminate closer than 4 feet horizontally
from any electric meter, gas meter, regulator, relief
valve or other equipment.
5. Where the vent penetrates the roof, the annular space
around the penetration must be permanently sealed
using approved materials to prevent entry of combustion products into the building.
6. Locate terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to
buildup of leaves or sediment.
7. Do not connect any other appliance to the vent pipe.
Prepare roof penetration
1. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or
noncombustible construction, size the vent pipe hole
at least 0.5” larger than the vent pipe diameter – use a
7” hole for 6” PVC or PP.
b. Insert a galvanized metal thimble in the vent pipe
hole.
2. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings and roofs.
3. Provide flashing and sealing boots sized for the vent
pipe and air pipe.
27
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Direct Exhaust #ATEGORY )) /NLY n 6ERTICAL (continued)
Termination and fittings
1. Prepare the vent termination coupling (Figure 15) by
inserting a bird screen. Bird screens are not supplied with the SlimFit boiler. Purchase separately
from Weil-McLain.
2. The vent piping must terminate in a coupling as shown
in Figure 15.
3. Maintain the required dimensions of the finished termination piping as shown in Figure 15.
4. Do not extend exposed vent pipe outside of building
more than shown in Figure 15. Condensate could freeze
and block vent pipe.
&IGURE DIRECT EXHAUST — Vertical termination
Multiple vent terminations
When terminating multiple SlimFit boilers, terminate
each vent connection as described in this section. Space
terminations as required for best installation practices and
required maintenance.
Complete termination preparation
Install vent terminations before proceeding. See previous
pages for instructions.
Installing direct exhaust vent piping
1. For reference in the following see:
a. Vertical terminations: see Figure 14, page 27.
2. Work from the boiler to vent or air termination. Do
not exceed the lengths given in the previous pages for
either the air or vent piping.
a. You must install appropriate pipe reducers, where
required, at the boiler vent connection.
3. Cut pipe to required lengths.
4. Deburr inside and outside of pipe ends.
5. Chamfer outside of each pipe end to ensure even cement
distribution when joining.
6. Clean all pipe ends and fittings. Dry thoroughly.
7. Dry assemble entire vent or air piping to ensure proper
fit before assembling any joint.
8. For each PVC/CPVC joint:
a. Handle fittings and pipes carefully to prevent contamination of surfaces.
b. For PVC/CPVC apply primer liberally to both joint
surfaces — pipe end and fitting socket.
c. While primer is still damp, lightly apply approved
cement to both surfaces in a uniform coating.
d. Apply a second coat to both surfaces. Avoid using
too much cement on sockets to prevent cement
buildup inside.
28
e. With cement still wet, insert pipe into fitting, twisting ¼
turn. Make sure pipe is fully inserted.
f. Wipe excess cement from joint. Check joint to be sure a
smooth bead of cement shows around the entire joint.
9. For polypropylene applications follow manufacturer’s instructions for preparation and assembly.
10. Install pipe supports as shown on Figure 14, page 27.
11. Slope vent and air piping continuously toward boiler, with at
least 1/4 inch drop per foot of run. Do not allow sags at any
point.
12. Maintain minimum clearance of ³⁄₁₆ inch between vent pipe
and any combustible wall or material.
13. Seal wall or floor penetration openings following local code
requirements.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT EXHAUST — Boiler room air openings
Combustion air provision
Special considerations
The SlimFit Commercial boiler can use inside air if no contaminants are
present in the boiler space. (If contaminants are likely to be present, install
the boiler as a direct vent appliance, using the appropriate vent instructions
in this manual, see Figure 12, page 22)
Tight construction
ANSI Z223.1 defines unusually tight construction
where:
The boiler room must be fitted with combustion air openings large enough
to provide air for all appliances in the room. Use the following information
to size the openings. Ensure the installation complies with all applicable
codes and standards.
Sizing combustion air openings
Air openings provide for ventilation (as well as combustion air) to prevent
overheating of the boiler controls and boiler space. Air is also needed for
other appliances located in the same space.
Use Figure 16, page 30, selecting the appropriate installation conditions.
Air openings must be sized to handle all appliances and air
movers (exhaust fans, etc.) using the air supply.
The sizing given in Figure 16, page 30 is based on the National Fuel Gas
Code, ANSI Z223.1, allowing adequate air openings for gravity-vented gas
appliances (Category I) in addition to that needed for the SlimFit boiler.
The SlimFit Commercial boiler is rated Category IV (pressurized vent),
and has varying requirements for combustion and ventilation air, reflected
by the special sizing instructions given in this manual.
1. Walls and ceilings exposed to the outside atmosphere have a continuous water vapor retarder with
a rating of 1 perm or less with openings gasketed,
and . . .
2. Weather-stripping has been added on openable
windows and doors, and . . .
3. Caulking or sealants are applied to areas such as
joints around windows and door frames, between
sole plates and floors, between wall-ceiling joints,
between wall panels, at penetrations for plumbing,
electrical, and gas lines, and in other openings.
For buildings with such construction, provide air
openings into the building from outside, sized per the
appropriate case in Figure 16, page 30 if appliances are
to use inside air for combustion and ventilation.
Exhaust fans and air movers
The appliance space must never be under a negative
pressure unless all appliances are installed as direct
vent. Always provide air openings sized not only to the
dimensions required for the firing rate of all appliances,
but also to handle the air movement rate of the exhaust
fans or air movers using air from the building or space.
Motorized air dampers
The air openings recommended in Figure 16, page 30 will allow adequate
ventilation and combustion air provided the boiler room is not subjected
to negative pressure due to exhaust fans or other mechanical ventilation
devices.
If the air openings are fitted with motorized dampers,
electrically interlock the damper to:
s
Prevent the boiler from firing if the damper is not
fully open.
Refer to the National Fuel Gas Code for dealing with other conditions.
s
Shut the boiler down should the damper close during boiler operation.
Free area — louver allowance
To accomplish this interlock, wire an isolated contact
(proving the damper open) in series with the thermostat input to the boiler. The boiler will not start if this
contact is open, and will shut down should it open
during operation.
The free area of openings means the area after reduction for any installed
louvers or grilles. Be sure to consider this reduction when sizing the air
openings.
Part number 550-100-168/0516
29
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT EXHAUST — Boiler room air openings (continued)
&IGURE MINIMUM combustion air openings for direct exhaust applications — !,, /0%.).' 3):%3 !2% &2%% !2%!
Provisions for combustion and ventilation air to be in 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.
Air openings
The required air opening sizes below are FREE AREA,
after reduction for louver obstruction. Note the exception below for large spaces.
SlimFit boiler
WITH other
appliances in room
SlimFit boiler
WITHOUT other
appliances in room
47/ openings, each at least:
1 square inch per Btuh
47/ openings, each at least:
1 square inch per Btuh
of all appliances in the room
of all appliances in the room
47/ openings, each at least:
1 square inch per Btuh
47/ openings, each at least:
1 square inch per Btuh
of all appliances in the room
— OR —
/.% opening **, each at least:
1 square inch per Btuh
of all appliances in the room
of all appliances in the room
— OR —
/.% opening **, each at least:
1 square inch per Btuh
of all appliances in the room
47/ openings, each at least:
1 square inch per Btuh
47/ openings, each at least:
1 square inch per Btuh
of all appliances in the room
— OR —
/.% opening **, each at least:
1 square inch per Btuh
of all appliances in the room
of all appliances in the room
— OR —
/.% opening **, each at least:
1 square inch per Btuh
of all appliances in the room
47/ openings, each at least:
1 square inch per Btuh
47/ openings, each at least:
1 square inch per Btuh
of all appliances in the room
— OR —
/.% opening **, each at least:
1 square inch per Btuh
of all appliances in the room
of all appliances in the room
— OR —
/.% opening **, each at least:
1 square inch per Btuh
of all appliances in the room
A single combustion air opening can be used for cases B, C or D above, sized as listed,
provided that:
./4)#%
2EQUIREMENTS FOR USING THE 3).',% AIR OPEN
ING OPTION
30%#)!, %8#%04)/. &/2 ,!2'% 30!#%3
s
s
s
The single opening must communicate directly to the outdoors or to a space that
communicates directly with outdoors (NOT to an interior space).
The top of the opening must be within 12 inches of the ceiling.
The free area of the opening must be at least equal to the sum of the areas of all
equipment vent connectors in the space.
NO combustion air openings are needed when the boiler (and other appliances) are installed
in a space with a volume NO LESS than 50 cubic feet per 1,000 Btuh of all appliances in
the space. That is, total the input of all appliances in MBH (1,000’s of Btuh), then multiply
this total times 50. The building MUST NOT be of tight construction.
Example: For a total input of 1500 MBH (1,500,000 Btuh) and an 8-foot ceiling height,
the minimum volume would be 50 x 1500 x 8 = 60,000 cubic feet.
30
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT EXHAUST — Sidewall
&IGURE $)2%#4 %8(!534 ˆ 3IDEWALL
TERMINATION
Allowable vent pipe materials
1. Use only the materials listed in Figure 13, page 23.
2. Install a bird screen in each vent pipe termination (coupling or elbow).
Bird screens are supplied with the boiler. Cut to size if necessary to fit
vent pipe size used.
Maximum piping length
1. Locate the termination such that the total vent piping from the boiler to
the termination will not exceed the maximum length given in Figure 19.
2. Maximum lengths listed in Figure 19 allow for 2 elbows. Additional
elbows require a reduction in maximum length as explained in the
table notes.
Connecting from termination to boiler
1. Install the terminations as instructed in the following. Then proceed
to page 45 to complete the vent piping between the termination and
the boiler.
&IGURE Maximum piping lengths for DIRECT EXHAUST sidewall
termination
"OILER
-!8)-5- PIPING LENGTH FOR PIPE DIAMETER INCH
DIRECT EXHAUST — Sidewall
termination — installation
sequence
Feet
adapter at each boiler fitting where stainless steel pipe will be connected.
3TEP Install the boiler.
3TEP Determine the proper location for wall
penetration for each termination.
s Prepare wall penetrations before
installing vent piping.
s Finish by attaching external pipe and
fittings as shown in the termination
instructions.
s Support vertical runs on the outside
of the building with brackets as
shown in the termination instructions.
INCH
SF-550
30
2
100
2
SF-750
Not allowed
30
2
*
3TAINLESS STEEL PIPE — Install required
INCH
PP, PVC, CPVC, ABS, AL29-4C SS
Elbows **
Feet
Elbows **
Feet
Elbows **
Not allowed
100
2
For 4-inch or 6-inch piping, install a pipe reducer directly at the boiler connection,
oriented vertically. Install reducer above the required adapter if using stainless steel
piping.
** For piping using more than 2 elbows, reduce maximum allowable length by 7 feet for
each additional elbow (90° or 45°). ADD 14 feet to maximum allowable length if the
sidewall termination uses a coupling instead of two elbows.
Determine location for sidewall termination
A gas vent extending through an exterior wall shall not
terminate adjacent to the wall or below building extensions
such as eaves, parapets, balconies or decks, except as otherwise
instructed in this manual or local codes. Failure to comply
could result in severe personal injury, death or substantial
property damage.
Place the vent terminations using the following guidelines.
3TEP Install vent piping from boiler to termination.
s Install a hanger support within
6 inches of any upturn in the piping.
s Slope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.
3TEP Connect the vent piping at the boiler
per manual instructions.
Part number 550-100-168/0516
1. Terminate the vent piping with a coupling as shown in Figure 18,
page 32. The coupling must butt against the outside wall plate. If vent
piping is extended outside, install a coupling at the outer plate and
continue vent piping from the coupling (or elbow when snorkeling as
in Figure 18, page 32 right side).
a. Apply the configuration on the left side of Figure 18 unless the
termination would fail to meet minimum clearance to grade or
snow line.
b. Apply the configuration on the right side of Figure 18 when the
termination needs to be raised higher to meet clearance to grade
or snow line.
31
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT EXHAUST — Sidewall (continued)
c. The vent pipe may run up as high as 4 feet, as shown in Figure 18 right side, with no enclosure. The vent pipe must be
secured with braces, and maintain all required clearances.
d. Space braces no further than 24 inches apart. (See WARNING
below for extremely cold climates.)
e. External venting greater than 4 feet requires an enclosure
around the vent pipe. The vent termination must exit through
the enclosure as shown in Figure 18, maintaining all required
clearances.
&IGURE DIRECT EXHAUST — Sidewall —
clearances to openings
Do not exceed the maximum length of the outside vent
piping shown in Figure 18. Excessive length exposed to
the outside could cause freezing of condensate in the vent
pipe, resulting in potential boiler shutdown. In extremely
cold climates, install an insulated chase around the vent
piping, particularly when using longer lengths. The chase
must allow for inspection of the vent pipe, and insulation
must be protected from water.
&IGURE DIRECT EXHAUST — Sidewall — configuration
options and minimum clearances
&IGURE DIRECT EXHAUST — Sidewall —
clearances from vent exit to forced air
intake
2. Consider the surroundings when terminating the vent:
a. Position the vent termination where vapors will not damage
nearby shrubs, plants or air conditioning equipment or be
objectionable.
b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct
window views.
c. Prevailing winds could cause freezing of condensate and water/
ice buildup where flue products impinge on building surfaces
or plants.
d. Avoid possibility of accidental contact of flue products with
people or pets.
e. Do not locate the terminations where wind eddies could affect
performance, such as inside building corners, near adjacent
buildings or surfaces, window wells, stairwells, alcoves, courtyards or other recessed areas.
32
f. Do not terminate above any door or window or
under a deck. Condensate can freeze, causing ice
formations.
g. Locate or guard vent to prevent condensate damage
to exterior finishes.
3. Maintain clearances as shown in the illustrations in this
manual section. Also maintain the following:
a. Vent must terminate:
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At lease 3 feet above any forced air intake within
10 feet.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT EXHAUST — Sidewall (continued)
s
No closer than 48 inches below or horizontally from any
door or window or any other gravity air inlet.
b. Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve or other equipment.
&IGURE DIRECT EXHAUST — Sidewall —
termination assembly — all parts by
installer
4. Because the SF-550 and SF-750 are Category IV appliances, the National Fuel Gas Code, ANSI Z223.1, requires that the vent must not
terminate over a public walkway or over an area where condensate
or vapor could create a nuisance or hazard, or could be detrimental
to the operation of regulators, relief valves, or other equipment.
5. Where the vent penetrates an outside wall, the annular space
around the penetration must be permanently sealed using approved materials to prevent entry of combustion products into
the building.
6. Locate termination so it is not likely to be damaged by foreign
objects, such as stones or balls, or subject to buildup of leaves or
sediment.
7. Do not connect any other appliance to the vent pipe. Do not connect multiple boilers to a common vent pipe.
Completing the vent piping
1. Install vent penetrations as explained in the following pages before
installing vent piping from the boiler to the terminations.
2. Insert piping from boiler vent connections, then attach exterior
termination piping.
3. Follow instructions beginning on page 45 to complete piping from
boiler to termination.
Multiple vent terminations
1. When terminating multiple direct exhaust SlimFit boilers, terminate each vent connection as described in this manual for individual
vents. Space terminations as required for best installation practices
and required maintenance.
1 Vent piping
2 Cover plates
3 Galvanized thimble
4 Vent elbow
5 Bird screen
Prepare wall penetrations
1. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole at least 0.4”
larger than the vent pipe diameter:
s
7” hole for 6” PP and PVC
s
9” hole for 8” PP and PVC
b. Insert a galvanized metal thimble in the vent pipe hole as
shown in Figure 35.
2. Use metal cover plates at wall penetrations.
3. Follow all local codes for isolation of vent pipe when passing
through floors or walls.
4. Seal exterior openings thoroughly with exterior caulk.
Part number 550-100-168/0516
Termination and fittings
1. Prepare the vent termination elbow (Figure 18, page 32)
by inserting a bird screen. Bird screens are supplied
with the boiler, and may have to be trimmed to size for
smaller vents.
2. You can install the vent termination using either of the
configurations shown in Figure 18, page 32.
3. Maintain the required dimensions of the finished termination piping as shown in Figure 18, page 32.
4. Do not extend exposed vent pipe outside of the building
more than shown in this document. Condensate could
freeze and block vent pipe.
33
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT EXHAUST — Vertical
&IGURE DIRECT EXHAUST vertical termination
Allowable vent pipe materials
1. Use only the materials listed in Figure 13, page 23.
2. Install a bird screen in each vent termination (coupling or elbow).
Bird screens are supplied with the boiler. Cut to size if necessary to fit
vent pipe size used.
Maximum piping length
1. Locate the terminations such that the total vent piping from the boiler to
the termination will not exceed the maximum length given in Figure 24.
2. Maximum lengths listed in Figure 24 allow for 2 elbows. Additional
elbows require a reduction in maximum length as explained in the
table notes.
Connecting from termination to boiler
1. Install the termination as instructed in the following. Then proceed
to page 45 to complete the vent piping between the termination and
the boiler.
&IGURE Maximum piping lengths for DIRECT EXHAUST vertical
termination
"OILER
-!8)-5- PIPING LENGTH FOR PIPE DIAMETER INCH
DIRECT EXHAUST — Vertical
termination — installation
sequence
Feet
adapter at each boiler fitting where stainless steel pipe will be connected.
3TEP Install the boiler.
3TEP Determine the proper location for wall
penetration for each termination.
s Prepare roof penetrations before
installing vent piping.
s Finish by attaching external pipe and
fittings as shown in the termination
instructions.
s Install terminations as described in
this manual.
s Support vertical runs on the outside
of the building with brackets as
shown in the termination instructions.
3TEP Install vent piping from boiler to termination.
s Install a hanger support within
6 inches of any upturn in the piping.
s Slope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.
3TEP Connect the vent piping at the boiler
per manual instructions.
34
INCH
SF-550
30
2
100
2
SF-750
Not allowed
30
2
*
3TAINLESS STEEL PIPE — Install required
INCH
PP, PVC, CPVC, ABS, AL29-4C SS
Elbows **
Feet
Elbows **
Feet
Elbows **
Not allowed
100
2
For 4-inch or 6-inch piping, install a pipe reducer directly at the boiler connection,
oriented vertically. Install reducer above the required adapter if using stainless steel
piping.
** For piping using more than 2 elbows, reduce maximum allowable length by 7 feet for
each additional elbow (90° or 45°).
Determine location for vertical termination
1. Locate the vent termination using the following guidelines:
2. The vent piping must terminate in a coupling as shown in Figure 25,
page 35.
3. Consider the surroundings when terminating the vent:
a. Position the vent termination where vapors will not damage nearby
shrubs, plants or air conditioning equipment or be objectionable.
b. The flue products will form a noticeable plume as they condense in
cold air. Avoid areas where the plume could obstruct window views.
c. Prevailing winds could cause freezing of condensate and water/ice
buildup where flue products impinge on building surfaces or plants.
d. Avoid possibility of accidental contact of flue products with people
or pets.
e. Do not locate the termination where wind eddies could affect performance or cause recirculation, such as inside building corners,
near adjacent buildings or surfaces, window wells, stairwells, alcoves,
courtyards or other recessed areas.
f. Locate or guard vent to prevent condensate damage to exterior
finishes.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT EXHAUST — Vertical (continued)
4. Maintain clearances as shown in the illustrations in this manual
section. Also maintain the following:
&IGURE DIRECT EXHAUST — Vertical termination
a. Vent must terminate:
s
At least 12 inches above roof or snow line as shown in
Figure 25.
s
At least 6 feet from adjacent walls.
s
No closer than 5 feet below roof overhang.
s
At least 3 feet above any forced air intake within 10 feet.
s
No closer than 48 inches below or horizontally from any
door or window or any other gravity air inlet.
b. Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve or other equipment.
5. Where the vent penetrates the roof, the annular space around the
penetration must be permanently sealed using approved materials
to prevent entry of combustion products into the building.
6. Locate terminations so they are not likely to be damaged by foreign
objects, such as stones or balls, or subject to buildup of leaves or
sediment.
7. Do not connect any other appliance to the vent pipe. Do not connect multiple boilers to a common vent pipe.
Prepare roof penetrations
1. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole at least 0.5”
larger than the vent pipe diameter:
s
7” hole for 6” PP and PVC.
s
9” hole for 8” PP and PVC.
b. Insert a galvanized metal thimble in the vent pipe hole.
2. Follow all local codes for isolation of vent pipe when passing
through floors, ceilings and roofs.
2. The vent piping must terminate in a coupling as shown
in Figure 25.
3. Maintain the required dimensions of the finished termination piping as shown in Figure 25.
4. Do not extend exposed vent pipe outside of building
more than shown in this document. Condensate could
freeze and block vent pipe.
3. Provide flashing and sealing boots sized for the vent pipe and air
pipe.
Multiple vent terminations
Termination and fittings
1. When terminating multiple SlimFit boilers, terminate
each vent connection as described in this section. Space
terminations as required for best installation practices
and required maintenance.
1. Prepare the vent termination coupling (Figure 25) by inserting a
bird screen. Bird screens are supplied with the boiler. Cut to size if
necessary to fit vent pipe size used.
Part number 550-100-168/0516
35
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT VENT — Boiler room air openings
Combustion/ventilation air provision
For direct vent installations, combustion air must be ducted directly from
outside to the SlimFit boiler air intake fitting. Two options are available:
sidewall or vertical direct vent. Though combustion air is ducted to the
SlimFit boiler, the boiler room will still require air openings, either for
ventilation or for combustion air for other appliances plus ventilation.
Sizing air openings
Air openings provide for ventilation (as well as combustion air) to prevent
overheating of the boiler controls and boiler space. Air is also needed for
other appliances located in the same space.
Motorized air dampers
If the air openings are fitted with motorized dampers,
electrically interlock the damper to:
s 0REVENT THE BOILER FROM lRING IF THE DAMPER IS NOT
fully open.
s 3HUT THE BOILER DOWN SHOULD THE DAMPER CLOSE DURing boiler operation.
To accomplish this interlock, wire an isolated contact
(proving the damper open) in series with the thermostat input to the boiler. The boiler will not start if this
contact is open, and will shut down should it open
during operation.
Use Figure 27, page 37, selecting the appropriate installation conditions.
Air openings must be sized to handle all appliances and air
movers (exhaust fans, etc.) using the air supply.
The sizing given in Figure 27, page 37 is based on the National Fuel Gas
Code, ANSI Z223.1, allowing adequate air opening for gravity-vented gas
appliances (Category I) when located in the same space as the SlimFit boiler.
When outside air is ducted as directed in this manual, the SlimFit boiler is
rated as direct vent (pressurized vent), and has varying requirements for
combustion and ventilation air, reflected by the special sizing instructions
given in Figure 27, page 37.
The air openings recommended in Figure 27, page 37 will allow adequate
ventilation and combustion air provided the boiler room is not subjected
to negative pressure due to exhaust fans or other mechanical ventilation devices. Refer to the National Fuel Gas Code for dealing with other conditions.
Louver allowance
The free area of openings means the area after reduction for any installed
louvers or grilles. Be sure to consider this reduction when sizing the air
openings.
Special considerations
Tight construction
ANSI Z223.1 defines unusually tight construction where:
1. Walls and ceilings exposed to the outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings
gasketed, and . . .
2. Weather-stripping has been added on openable windows and doors,
and . . .
3. Caulking or sealants are applied to areas such as joints around windows
and door frames, between sole plates and floors, between wall-ceiling
joints, between wall panels, at penetrations for plumbing, electrical,
and gas lines, and in other openings.
For buildings with such construction, provide air openings into the building from outside, sized per the appropriate case in Figure 27, page 37 if
appliances are to use inside air for combustion and ventilation.
Manifolded combustion air option
1. Multiple SlimFit boilers can use a common combustion air manifold.
a. See Figure 104, page 122 for minimum cross
sectional area of combined air ducts.
b. Provide minimum clearance to adjacent vents
and grade/snow line as shown in Figure 26.
c. Provide minimum free area in duct (adjusted
for louver restriction) of SQUARE INCH PER
"TUH total boiler input, or divide the
total MBH (1000’s Btuh) by 2.
d. Example: For an MBS system with total input
of 3,000,000 Btuh, or 3,000 MBH: Divide 3,000
by 2 = 1500 square inches minimum for a combined air duct.
e. If combustion air damper is used, wire to boilers
to prevent operation except after damper has
opened (see Motorized air dampers, above).
/.,9 AIR PIPING CAN BE COMBINED
$/ ./4 USE COMBINED VENT PIPING
&LUE GAS LEAKAGE AND BOILER COM
PONENT DAMAGE CAN OCCUR &AILURE
TO COMPLY COULD RESULT IN SEVERE
PERSONAL INJURY DEATH OR SUBSTANTIAL
PROPERTY DAMAGE
&IGURE Manifolded combustion air option
Exhaust fans and air movers
The appliance space must never be under a negative pressure unless all
appliances are installed as direct vent. Always provide air openings sized
not only to the dimensions required for the firing rate of all appliances,
but also to handle the air movement rate of the exhaust fans or air movers
using air from the building or space.
36
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT VENT — Boiler room air openings (continued)
&IGURE MINIMUM combustion air openings for direct vent applications — !,, /0%.).' 3):%3 !2% &2%% !2%!
Provisions for combustion and ventilation air to be in 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.
Air openings
SlimFit boiler
WITH other
appliances in room
The required air opening sizes below are FREE AREA,
after reduction for louver obstruction. Note the exception below for large spaces.
47/ openings, each at least:
1 square inch per Btuh
of all other appliances in the room
47/ openings, each at least:
1 square inch per Btuh
of all other appliances in the room
— OR —
/.% opening **, each at least:
1 square inch per Btuh
of all other appliances in the room
47/ openings, each at least:
1 square inch per Btuh
of all other appliances in the room
— OR —
/.% opening **, each at least:
1 square inch per Btuh
of all other appliances in the room
47/ openings, each at least:
1 square inch per Btuh
of all other appliances in the room
— OR —
/.% opening **, each at least:
1 square inch per Btuh
of all other appliances in the room
SlimFit boiler
WITHOUT other
appliances in room
./ openings are required if the
boiler installation provides at least the
Recommended service clearances
shown on page 6.
If the space is smaller, provide ONE
opening to a larger room with at least
1 square inch per Btuh
of SlimFit boiler input.
./ openings are required if the
boiler installation provides at least the
Recommended service clearances
shown on page 6.
If the space is smaller, provide ONE
opening to a larger room with at least
1 square inch per Btuh
of SlimFit boiler input.
./ openings are required if the
boiler installation provides at least the
Recommended service clearances
shown on page 6.
If the space is smaller, provide ONE
opening to a larger room with at least
1 square inch per Btuh
of SlimFit boiler input.
./ openings are required if the
boiler installation provides at least the
Recommended service clearances
shown on page 6.
If the space is smaller, provide ONE
opening to a larger room with at least
1 square inch per Btuh
of SlimFit boiler input.
A single combustion air opening can be used for cases B, C or D above, sized as listed,
provided that:
./4)#%
2EQUIREMENTS FOR USING THE 3).',% AIR OPEN
ING OPTION
30%#)!, %8#%04)/. &/2 ,!2'% 30!#%3
s
s
s
The single opening must communicate directly to the outdoors or to a space that
communicates directly with outdoors (NOT to an interior space).
The top of the opening must be within 12 inches of the ceiling.
The free area of the opening must be at least equal to the sum of the areas of all
equipment vent connectors in the space.
NO combustion air openings are needed when the boiler (and other appliances) are installed
in a space with a volume NO LESS than 50 cubic feet per 1,000 Btuh of all appliances in
the space. That is, total the input of all appliances in MBH (1,000’s of Btuh), then multiply
this total times 50. The building MUST NOT be of tight construction.
Example: For a total input of 1500 MBH (1,500,000 Btuh) and an 8-foot ceiling height,
the minimum volume would be 50 x 1500 x 8 = 60,000 cubic feet.
Part number 550-100-168/0516
37
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT VENT — Sidewall
&IGURE $)2%#4 6%.4 SIDEWALL TERMINATION
Allowable vent/air pipe materials
1. Use only the materials listed in Figure 13, page 23.
2. Install a bird screen in each vent and air pipe termination. Bird screens
are supplied with the boiler. Cut to size if necessary to fit vent pipe
size used.
Maximum piping length
1. Locate the terminations such that the total air piping and vent piping
from the boiler to the termination will not exceed the maximum length
given in Figure 29.
2. Maximum lengths listed in Figure 29 allow for 2 elbows. Additional
elbows require a reduction in maximum length as explained in the
table notes.
Connecting from termination to boiler
1. Install the terminations as instructed in the following. Then proceed to
page 45 to complete the air and vent piping between the termination
and the boiler.
&IGURE Maximum piping lengths for DIRECT VENT sidewall
termination
DIRECT VENT — Sidewall
termination with separate vent
and air pipes — installation
sequence
"OILER
-!8)-5- PIPING LENGTH FOR PIPE DIAMETER INCH
Feet
3TAINLESS STEEL PIPE — Install required
adapter at each boiler fitting where stainless steel pipe will be connected.
3TEP Install the boiler.
3TEP Determine the proper location for wall
penetration for each termination.
s Prepare wall penetrations before
installing vent and air piping.
s Finish by attaching external pipe and
fittings as shown in the termination
instructions.
s Install termination assembly as
described in this manual.
s Support vertical runs on the outside
of the building with brackets as
shown in the termination instructions.
3TEP Install air and vent piping from boiler
to termination.
s Install a hanger support within
6 inches of any upturn in the piping.
s Slope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.
3TEP Connect the vent and air piping at the
boiler per manual instructions.
38
INCH
INCH
PP, PVC, CPVC, ABS, AL29-4C SS
Elbows **
Feet
Elbows **
Feet
SF-550
30
2
100
2
SF-750
Not allowed
30
2
*
Elbows **
Not allowed
100
2
For 4-inch or 6-inch piping, install a pipe reducer directly at the boiler connection,
oriented vertically. Install reducer above the required adapter if using stainless steel
piping.
** For piping using more than 2 elbows, reduce maximum allowable length by 7 feet for
each additional elbow (90° or 45°).
Determine location for termination
A gas vent extending through an exterior wall shall not
terminate adjacent to the wall or below building extensions
such as eaves, parapets, balconies or decks, except as otherwise
instructed in this manual or local codes. Failure to comply
could result in severe personal injury, death or substantial
property damage.
1. Place the vent/air terminations using the following guidelines.
2. The vent and air piping must terminate as shown in Figure 30, page 39.
(The elbow at the exit opening must butt against the outside wall
plate.) This arrangement avoids recirculation of flue products into the
combustion air stream.
a. Apply the configuration on the left side of Figure 30 unless the
terminations would fail to meet minimum clearance to grade or
snow line.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT VENT — Sidewall (continued)
b. Apply the configuration on the right side of Figure 30 when
the terminations need to be raised higher to meet clearance to
grade or snow line.
c. The vent and air pipes may run up as high as 4 feet, as shown in
Figure 30 right side with no enclosure. The vent and air pipes
must be secured with braces, and all clearances and lengths
must be maintained. Space braces no further than 24 inches
apart. (See WARNING below for extremely cold climates.)
d. External venting greater than 4 feet requires an enclosure
around the vent and air pipes. The vent and air terminations
must exit through the enclosure as shown in Figure 30, maintaining all required clearances.
3. The vent piping must terminate in an elbow pointed outward or
away from the air inlet, as shown in Figure 30.
&IGURE Sidewall termination with separate pipes
— clearances to openings
Do not exceed the maximum lengths of the outside vent
piping shown in Figure 30. Excessive length exposed to
the outside could cause freezing of condensate in the vent
pipe, resulting in potential boiler shutdown. In extremely
cold climates, install an insulated chase around the vent
piping, particularly when using longer lengths. The chase
must allow for inspection of the vent pipe, and insulation
must be protected from water.
&IGURE DIRECT VENT — Sidewall — configuration
options and minimum clearances from vent to air
terminations
4. Consider the surroundings when terminating the vent and air:
a. Position the vent termination where vapors will not damage
nearby shrubs, plants or air conditioning equipment or be
objectionable.
b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct
window views.
c. Prevailing winds could cause freezing of condensate and water/
ice buildup where flue products impinge on building surfaces
or plants.
Part number 550-100-168/0516
&IGURE Sidewall termination with separate pipes
— clearances from vent exit to forced air
intake
Terminating with the vent elbow sideways
instead of pointed away from the building can
result in the possibility of ice build-up on the
side of the building.
If the vent/air pipes are extended out beyond
the wall, install a coupling at the exit opening,
with the coupling butted against the outside
plate. Then continue vent/air piping from the
coupling.
39
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT VENT — Sidewall (continued)
5.
6.
7.
8.
9.
d. Avoid possibility of accidental contact of flue products with
people or pets.
e. Do not locate the terminations where wind eddies could affect
performance or cause recirculation, such as inside building
corners, near adjacent buildings or surfaces, window wells,
stairwells, alcoves, courtyards or other recessed areas.
f. Do not terminate above any door or window or under a deck.
Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage to exterior
finishes.
Maintain clearances as shown in the illustrations in this manual
section. Also maintain the following:
a. Vent must terminate:
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At lease 3 feet above any forced air intake within 10 feet.
b. Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve or other equipment.
Because the SF-550 and SF-750 are condensing appliances, the National Fuel Gas Code, ANSI Z223.1, requires that the vent must not
terminate over a public walkway or over an area where condensate
or vapor could create a nuisance or hazard, or could be detrimental
to the operation of regulators, relief valves, or other equipment.
Where the vent or air pipe penetrates an outside wall, the annular
space around the penetration must be permanently sealed using
approved materials to prevent entry of combustion products into
the building.
Locate terminations so they are not likely to be damaged by foreign
objects, such as stones or balls, or subject to buildup of leaves or
sediment.
Do not connect any other appliance to the vent pipe or multiple
boilers to a common vent pipe.
&IGURE Multiple terminations — separate pipes —
clearance from vent of one to air intake of
the next
&IGURE Multiple terminations — separate pipes —
clearance from vent of one to air intake of
the next — alternate configuration of air
and vent terminations
Completing the vent/air piping
1. Install vent/air penetrations as explained in the following pages
before installing vent and air piping from the boiler to the terminations. Insert piping from boiler air and vent connections, then
attach exterior termination piping.
2. Follow instructions beginning on page 45 to complete piping from
boiler to termination.
Multiple vent/air terminations
1. When terminating multiple SlimFit boilers, terminate each vent/
air connection as described in this manual.
2.
3.
4.
5.
40
All vent pipes and air inlets must terminate at the same
height to avoid possibility of severe personal injury, death
or substantial property damage.
Place wall penetrations to obtain minimum clearance of 12 inches
between vent pipe and adjacent air inlet elbow, as shown in Figure 33, page 40 for U. S. installations.
For Canadian installations, provide clearances required by CSA
B149.1 or B149.2 Installation Code.
The air inlet of an SlimFit boiler is part of a direct vent connection.
It is not classified as a forced air intake with regard to spacing from
adjacent boiler vents.
Combustion air (NOT vent piping) can be manifolded as shown
in Figure 26, page 36.
If the vent/air pipes are extended out beyond
the wall, install a coupling at the exit opening,
with the coupling butted against the outside
plate. Then continue vent/air piping from the
coupling.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT VENT — Sidewall (continued)
Prepare wall penetrations
&IGURE DIRECT VENT — Sidewall — termination
assembly (all parts by installer, except the
bird screens)
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.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole at least 0.4”
larger than the vent pipe diameter:
s 7” hole for 6” PP and PVC
s 9” hole for 8” PP and PVC
b. Insert a galvanized metal thimble in the vent pipe hole as
shown in Figure 35.
3. Sidewall termination plates must be provided by the installer.
4. Follow all local codes for isolation of vent pipe when passing
through floors or walls.
5. Seal exterior openings thoroughly with exterior caulk.
Termination and fittings
1. Prepare the vent termination elbow and the air termination elbow
(Figure 35, page 41) by inserting a bird screen in each. Bird screens
are supplied with the boiler. Cut to size if necessary to fit vent pipe
size used.
2. When completed, the air termination elbow must be oriented
at least 20 inches (and no more than 36 inches) below the vent
termination, and at least 12 inches above grade or snow line as
shown in Figure 30, page 39.
3. You can orient the vent termination elbow either directly outward
or 90 degrees away from the air inlet elbow as shown in Figure 30,
page 39.
4. Maintain the required dimensions of the finished termination
piping as shown in Figure 30, page 39.
5. Do not extend exposed vent pipe outside of building more than
shown in this document. Condensate could freeze and block vent
pipe.
If the vent/air pipes are extended out beyond the wall,
install a coupling at the exit opening, with the coupling
butted against the outside plate. Then continue vent/air
piping from the coupling.
1
2
3
4
5
6
Vent piping
Air piping
Cover plates
Galvanized thimbles
Bird screen (air)
Air inlet elbow
7
8
9
10
11
Elbow
Nipple
Elbow (vent termination)
Alternate elbow orientation
Bird screen (vent termination)
Do not exceed the maximum lengths of the outside vent
piping shown in Figure 30, page 39. Excessive length exposed to the outside could cause freezing of condensate
in the vent pipe, resulting in potential boiler shutdown.
In extremely cold climates, install an insulated chase
around the vent piping, particularly when using longer
lengths. The chase must allow for inspection of the vent
pipe, and insulation must be protected from water.
Part number 550-100-168/0516
41
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT VENT — Vertical
&IGURE $)2%#4 6%.4 VERTICAL TERMINATION
Allowable vent/air pipe materials
1. Use only the materials listed in Figure 13, page 23.
2. Install a bird screen in each vent and air pipe termination. Bird screens
are supplied with the boiler. Cut to size if necessary to fit vent pipe
size used.
Maximum piping length
1. Locate the terminations such that the total air piping and vent piping
from the boiler to the termination will not exceed the maximum length
given in Figure 37.
2. Maximum lengths listed in Figure 37 allow for 2 elbows. Additional
elbows require a reduction in maximum length as explained in the
table notes.
Connecting from termination to boiler
1. Install the terminations as instructed in the following. Then proceed to
page 45 to complete the air and vent piping between the termination
and the boiler.
&IGURE Maximum piping lengths for DIRECT VENT vertical
termination
DIRECT VENT — Vertical
termination with separate vent
and air pipes — installation
sequence
3TAINLESS STEEL PIPE — Install required
"OILER
-!8)-5- PIPING LENGTH FOR PIPE DIAMETER INCH
Feet
INCH
INCH
PP, PVC, CPVC, ABS, AL29-4C SS
Elbows **
Feet
Elbows **
Feet
SF-550
30
2
100
2
SF-750
Not allowed
30
2
Elbows **
Not allowed
100
2
adapter at each boiler fitting where stainless steel pipe will be connected.
*
3TEP Install the boiler.
3TEP Determine the proper location for wall
penetration for each termination.
s Prepare roof penetrations before
installing vent and air piping.
s Finish by attaching external pipe and
fittings as shown in the termination
instructions.
s Install terminations as described in
this manual.
s Support vertical runs on the outside
of the building with brackets as
shown in the termination instructions.
** For piping using more than 2 elbows, reduce maximum allowable length by 7 feet for
each additional elbow (90° or 45°).
3TEP Install air and vent piping from boiler
to termination.
s Install a hanger support within
6 inches of any upturn in the piping.
s Slope horizontal piping downward
toward the boiler at least 1/4 inch
per foot.
3TEP Connect the vent and air piping at the
boiler per manual instructions.
42
For 4-inch or 6-inch piping, install a pipe reducer directly at the boiler connection,
oriented vertically. Install reducer above the required adapter if using stainless steel
piping.
Determine location for vertical terminations
1. Locate the vent/air terminations using the following guidelines:
2. The air piping must terminate in a down-turned 180-degree return
bend as shown in Figure 38, page 43. Locate the air inlet pipe no further
than 2 feet from the center of the vent pipe. This placement avoids
recirculation of flue products into the combustion air stream.
3. The vent piping must terminate in an up-turned coupling as shown in
Figure 38, page 43. The top of the coupling must be at least 1 foot above
the air intake. The air inlet pipe and vent pipe can be located in any
desired position on the roof, but must always be no further than 2 feet
apart and with the vent termination at least 1 foot above the air intake.
4. Consider the surroundings when terminating the vent and air:
a. Position the vent termination where vapors will not damage nearby
shrubs, plants or air conditioning equipment or be objectionable.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT VENT — Vertical (continued)
b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct
window views.
c. Prevailing winds could cause freezing of condensate and water/
ice buildup where flue products impinge on building surfaces
or plants.
d. Avoid possibility of accidental contact of flue products with
people or pets.
e. Do not locate the terminations where wind eddies could affect
performance or cause recirculation, such as inside building
corners, near adjacent buildings or surfaces, window wells,
stairwells, alcoves, courtyards or other recessed areas.
f. Do not terminate above any door or window. Condensate can
freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage to exterior
finishes.
h. Maintain clearances to vent termination as given below:
i. Vent must terminate:
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At least 3 feet above any forced air intake within 10 feet.
s No closer than 12 inches below or horizontally from any
door or window or any other gravity air inlet.
j. Air inlet must terminate at least 12 inches above the roof or
snow line and at least 12 inches below the vent termination as
shown in Figure 38.
k. Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve or other equipment.
5. Where the vent or air pipe penetrates the roof, the annular space
around the penetration must be permanently sealed using approved materials to prevent entry of combustion products into
the building.
6. Locate terminations so they are not likely to be damaged by foreign
objects, such as stones or balls, or subject to buildup of leaves or
sediment.
7. Do not connect any other appliance to the vent pipe or multiple
boilers to a common vent pipe.
&IGURE Vertical termination — separate pipes
Prepare roof penetrations
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.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole at least ½”
larger than the vent pipe diameter:
s 7” hole for 6” PP and PVC or 9” for 8” PP and PVC.
b. Insert a galvanized metal thimble in the vent pipe hole.
3. Space the air and vent holes to provide the minimum spacings
shown in Figure 38, page 43.
4. Follow all local codes for isolation of vent pipe when passing
through floors, ceilings and roofs.
5. Provide flashing and sealing boots sized for the vent pipe and air
pipe.
Termination and fittings
1. Prepare the vent termination coupling and the air termination
return bend (Figure 38, page 43) by inserting a bird screen in each.
Part number 550-100-168/0516
43
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIRECT VENT — Vertical (continued)
2.
3.
4.
5.
6.
Bird screens are supplied with the boiler. Cut to size if necessary
to fit vent pipe size used.
The air piping must terminate in a down-turned 180-degree return
bend as shown in Figure 38, page 43. Locate the air inlet pipe no
further than 2 feet from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion
air stream.
The vent piping must terminate in an up-turned coupling as shown
in Figure 38, page 43.
a. Vent must terminate:
s At least 6 feet from adjacent walls.
s No closer than 5 feet below roof overhang.
s At least 3 feet above any forced air intake within 10 feet.
s No closer than 12 inches below or horizontally from any
door or window or any other gravity air inlet.
The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet apart
and with the vent termination at least 1 foot above the air intake.
Maintain the required dimensions of the finished termination
piping as shown in Figure 38, page 43.
Do not extend exposed vent pipe outside of building more than
shown in this document. Condensate could freeze and block vent
pipe.
&IGURE Termination location — separate pipes —
terminations for multiple boilers
Multiple vent/air terminations (Figure 39)
1. When terminating multiple SlimFit boilers, terminate each vent/
air connection as described in this section.
Terminate all vent pipes at the same height and all air
pipes at the same height to avoid possibility of severe
personal injury, death or substantial property damage.
2. Place roof penetrations to obtain minimum clearance of 12 inches
between edge of air intake elbow and adjacent vent pipe of another
boiler for U. S. installations (see Figure 2). For Canadian installations, provide clearances required by CSA B149.1 or B149.2
Installation Code.
3. The air inlet of an SlimFit boiler is part of a direct vent connection.
It is not classified as a forced air intake with regard to spacing from
adjacent boiler vents.
44
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install vent/air piping — from termination to boiler
Complete termination preparation
&IGURE Boiler vent and air connections
1. Install vent and air terminations before proceeding. See previous
pages for instructions.
Pipe joint preparation and sealing
00 06# #06# OR !"3 PIPING
1. Dry assemble entire vent or air piping to ensure proper fit before
assembling any joint. Mark pipe with felt-tip pen to ensure full
insertion when completing each joint.
2. Cut pipe to required lengths.
3. Deburr inside and outside of pipe ends.
4. Chamfer outside of each pipe end to ensure even cement distribution when joining.
5. Clean all pipe ends and fittings. Dry thoroughly.
6. For each joint:
a. Handle fittings and pipes carefully to prevent contamination
of surfaces.
b. Apply primer liberally to both joint surfaces — pipe end and
fitting socket.
c. While primer is still damp, lightly apply approved cement to
both surfaces in a uniform coating.
d. Apply a second coat to both surfaces. Avoid using too much
cement on sockets to prevent cement buildup inside.
e. With cement still wet, insert pipe into fitting, twisting ¼ turn.
Make sure pipe is fully inserted.
f. Wipe excess cement from joint. Check joint to be sure a smooth
bead of cement shows around the entire joint.
Use cement sparingly. Excessive cement can cause blockage of the condensate opening.
!, # STAINLESS STEEL PIPING
1. Install the required stainless vent adapter at boiler vent connection,
following instructions supplied with the adapter.
2. Follow vent pipe manufacturer’s instructions for preparing and
sealing joints.
Installing vent and air piping
1. For reference in the following see:
a. DIRECT EXHAUST — Sidewall terminations: see Figure 17,
page 31.
b. DIRECT EXHAUST — Vertical terminations: see Figure 25,
page 35.
c. DIRECT VENT — Sidewall terminations: see Figure 28,
page 38.
d. DIRECT VENT — Vertical terminations: see Figure 36,
page 42.
2. Work from the boiler to vent or air termination. Do not exceed the
lengths given in the previous pages for either the air or vent piping.
a. As shown in the maximum length tables, the SF-550 must be
installed with only 6-inch vent and air piping.
b. As shown in the maximum length tables, the SF-750 may be
installed with either 6-inch or 8-inch vent and air piping.
c. SF-750 only — Install appropriate pipe reducers, when required, at both the boiler vent and air connections. Install
directly at the boiler, with reducer in the vertical orientation.
3. See Figure 40 for attaching vent and air pipes at the boiler.
Part number 550-100-168/0516
Inserting/securing vent or air
pipe into boiler connectors
3TAINLESS STEEL PIPE — Install required
1.
2.
3.
4.
adapter at each boiler fitting where stainless steel pipe will be connected.
Clean and chamfer insertion end of pipe. Deburr
inside of insertion end.
Inspect boiler vent or air adapter (above) — verify
no obstructions or foreign objects inside.
Measure 3½ inches from end of pipe and make
a mark with felt-tip pen before assembling joint.
Prepare and assemble joints per instructions at left.
Do not apply excessive force or bend the
adapter or flue/air pipe when inserting.
The adapter could be damaged.
4. Install pipe supports as shown in Figure 28, page 38 or
Figure 36, page 42.
5. Slope vent and air piping continuously toward boiler,
with at least ¼ inch drop per foot of run. Do not allow
sags at any point.
6. Maintain minimum clearance of ³⁄₁₆ inch between vent
pipe and any combustible wall or material.
7. Seal wall or floor penetration openings following local
code requirements.
45
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install condensate components
Install condensate drain tee
1. See Figure 41.
2. Remove PVC fittings and gasket from the accessories bag.
3. Deburr and chamfer outside and inside of 1” PVC
nipple (item 1) to ensure even cement distribution
when joining.
4. Clean nipple ends and all fittings. Dry thoroughly.
5. For each joint in the condensate line, apply the following. Assemble parts ONLY in the order given.
a. Apply primer liberally to both joint surfaces —
pipe end and fitting socket.
b. While primer is still damp, lightly apply approved cement to both surfaces in a uniform
coating.
c. Apply a second coat of cement to both surfaces.
Avoid using too much cement on sockets to
prevent cement buildup inside.
d. With cement still wet, insert pipe into fitting,
twisting ¼ turn. Make sure pipe is fully inserted.
e. Wipe excess cement from joint. Check joint to
be sure a smooth bead of cement shows around
the entire joint.
6. Assemble the 1” PVC nipple to the PVC condensate
drain tee (item 2). Insert the nipple completely into
the tee socket.
7. Allow joint to dry completely.
8. Slide the finished nipple/tee assembly into the
condensate drain hole.
9. Slide the gasket (item 3) over the nipple.
10. Cement the 1” coupling (item 4) to the protruding
1” nipple. Press together FIRMLY to ensure the
gasket is compressed for an air-tight seal. Hold in
place long enough for the PVC cement to set.
11. See Figure 42 for completed assembly.
&IGURE Condensate drain tee assembly
4
3
1
2
&IGURE Condensate drain tee, completed
Fittings must be firmly pressed in place to
ensure an air-tight seal.
Firmly press the coupling and the tee together while the cement sets to ensure the
gasket is securely compressed. The gasket
ensures the jacket enclosure is airtight at
this location.
Inside
46
Outside
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Install condensate components (continued)
Connect condensate trap
&IGURE Condensate trap installed (shown with
1. See Figure 44.
2. Remove the protector cap from the bottom of the PVC tee at the
heat exchanger condensate connection (location 2).
3. Slide a hose clamp over each end of the condensate trap line.
4. Slide the ends of the line onto the bottom of the PVC tee at the
heat exchanger condensate connection (location 2) and onto the
PVC coupling on the right (location 1).
5. Slide the hose clamps into position and tighten securely.
inlet air silencer hidden)
1
2
Connect condensate line
1. Connect condensate drain tubing to the 1” PVC condensate tee and
run to floor drain or condensate pump (see Figure 45). Use 1” PVC
or CPVC pipe; or install a hose barb fitting and connect tubing.
Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC
pipe must comply with ASTM D1785, F441 or D2665.
Cement and primer must comply with ASTM D2564
or F493. For Canada, use CSA or ULC certified PVC or
CPVC pipe, fittings and cement.
&IGURE Condensate pump (by others), typical
2. Leave the top of the 1” tee OPEN. This is needed as a vacuum break.
3. When installing a condensate pump, select one approved for use
with condensing boilers and furnaces. The pump should have an
overflow switch to prevent property damage from condensate
spillage. See Figure 43 for required flow capacity.
4. When sizing condensate pumps, make sure to include the total
load of all SlimFit boilers connected to it.
The condensate line must remain unobstructed, allowing free flow of condensate. If condensate is allowed to
freeze in the line or if the line is obstructed in any other
manor, condensate can exit from the boiler tee, resulting
in potential water damage to property.
Condensate from the SlimFit boiler will be slightly acidic
(typically with a pH from 3.2 to 4.5). Install a neutralizing
filter if required by local codes. See Replacement parts
section at the end of this manual for the Weil-McLain
kit.
&IGURE Condensate pump capacity, GPH
-INIMUM RECOMMENDED CONDENSATE PUMP
CAPACITY PER BOILER '0(
SF-550
14
Part number 550-100-168/0516
SF-750
20
For a condensate pump equipped with an
overflow switch, the switch can be connected
to the external manual reset or automatic
reset limit terminals of the Control. This
would shut down the boiler in the event of a
condensate overflow. See the wiring diagram
for location of the wiring terminals.
47
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Gas piping
Connecting gas supply piping
1. Remove jacket front panel. See Figure 46 to connect gas supply
pipe to the boiler.
a. Install a union for servicing, when required.
b. Install a manual shutoff valve in the gas supply piping, within
6 feet of the boiler.
c. In Canada, the manual gas valve must be identified by the
installer.
2. Support piping with hangers, not by the boiler or its accessories.
3. Purge all air from the gas supply piping.
4. Before placing the boiler in operation, check the boiler and its gas
connection for leaks.
a. Close manual main shutoff valve during any pressure testing
at less than 20” w.c.
b. Disconnect the boiler gas connection from the gas supply piping during any pressure testing greater than 20” w.c.
5SE TWO WRENCHES WHEN TIGHTENING
GAS PIPING AT BOILER, using one wrench
to prevent the boiler gas line connection
from turning. Failure to support the
boiler gas connection pipe to prevent
it from turning could damage gas line
components.
&IGURE Connect gas supply piping
Do not check for gas leaks with an open flame — use
a soapy water bubble test. Failure to eliminate gas leaks
can cause severe personal injury, death or substantial
property damage.
5. Use pipe dope compatible with propane gases. Apply sparingly
only to male threads of pipe joints so that pipe dope does not
block gas flow.
Failure to apply pipe dope as detailed above can result
in severe personal injury, death or substantial property
damage.
SlimFit boilers are shipped ready to fire natural gas ONLY.
You must install the propane conversion kit if the boiler
will be connected to propane. See page 8 through page 10
for instructions. Failure to comply could result in severe
personal injury, death or substantial property damage.
Install a 100% lockup gas pressure regulator in the gas
supply line if inlet pressure can exceed 14” w.c. at any
time. Adjust the lockup regulator for 7 to 10” w.c. inlet
pressure. This setting provides a cushion below the setting of the high gas pressure switch. Failure to comply
could result in shutdown by the high gas pressure switch,
resulting in possible serious property damage due to
freeze-up.
&IGURE Location of gas train inlet pressure tap
Gas valve
Tee
Natural Gas:
Pipe sizing for natural gas
1. Size gas supply piping from meter outlet to entrance of boiler in
accordance with Figure 49 and Figure 50, page 49. Gas pipe must
be properly sized with a 100% lockup gas pressure regulator in
the gas supply line. An undersized gas pipe feeding the boiler(s)
can cause problems.
2. Use the total input of all boilers. Divide the total input in Btuh by
1,000 to obtain cubic feet per hour of natural gas.
a. Pipe lengths in Figure 49 are equivalent lengths of straight
pipe. Use Figure 50 to determine equivalent length of fittings.
b. Figure 49 is only for natural gas with specific gravity 0.60, with
a pressure drop through the gas piping of 0.30” w.c.
c. For additional gas pipe sizing information, refer to ANSI Z223.1
(or B149.1 or B149.2 for Canadian installations).
48
Low gas
pressure switch
High gas
pressure switch
Remove plug and connect manometer at
this point.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Gas piping (continued)
Natural gas supply pressure
&IGURE Common gas line for multiple boilers
1. Pressure required at gas pressure tap near boiler gas
connection (see Figure 46, page 48):
a. Maximum: 14” w.c. with no flow (lockup) or
with boiler on.
b. Minimum: 3.5” w.c. with gas flowing (verify
during boiler startup, while boiler is at high
fire).
c. If no external pressure tap is available, connect manometer to the gas pressure switch tee
(Figure 47, page 48). At this point, the minimum gas pressure required is 3.0” w.c.
Propane Gas:
You must follow the instructions in this
manual, beginning on page 8, to operate
the boiler on propane. Failure to comply
could result in severe personal injury,
death or substantial property damage.
Pipe sizing for propane gas
1. Contact gas supplier to size pipes, tanks and 100%
lockup gas pressure regulator. Gas pipe must be
properly sized with a 100% lockup gas pressure
regulator in the gas supply line. An undersized gas
pipe feeding the boiler(s) can cause problems.
Propane supply pressure
1. Pressure required at gas pressure tap near boiler gas
connection (see Figure 46, page 48):
a. Maximum: 14” w.c. with no flow (lockup) or
with boiler on.
b. Minimum: 3.5” w.c. with gas flowing (verify
during boiler startup, while boiler is at high
fire).
c. If no external pressure tap is available, connect
manometer to the gas pressure switch tee (Figure 47, page 48). At this point, the minimum
gas pressure required is 3.0” w.c.
Manifolded gas supply lines
1. Construct gas header for multiple boilers using
Figure 48 and the sizing tables below. Refer to the
National Fuel Gas Code for other conditions.
2. Provide manual shutoff gas valve, union and sediment trap (minimum 3 inches below tee) as shown
in Figure 46, page 48 and Figure 48 for each boiler.
3. A 1¼” NPT gas piping riser from header to boiler
will be large enough for most jobs. Ensure the piping is large enough so that the minimum pressure
at the boiler, with all connected appliances firing,
will be as specified on page 49 (natural gas) or
page 49 (propane).
4. A 100% lockup regulator should be installed per the
regulator manufacturers installation instructions.
Part number 550-100-168/0516
&IGURE Pipe capacity for natural gas
'AS PIPE
TOTAL
LENGTH
FEET
10
20
30
40
50
75
100
150
'AS SUPPLY PIPE CAPACITY CUBIC FEET PER HOUR
v WC PRESSURE DROP
(cubic feet per hour, 0.60 specific gravity)
v
v
v
v
1050
730
590
500
440
360
305
250
1600
1100
890
760
670
545
460
380
3050
2100
1650
1450
1270
1020
870
710
4800
3300
2700
2300
2000
1650
1400
1130
&IGURE Equivalent lengths of straight pipe for gas line fittings
%QUIVALENT LENGTH FEET
0IPE SIZE
inches
— %LBOW
4EE
1¼
1½
2
2½
3.45
4.02
5.17
6.16
6.90
8.04
10.3
12.3
Gas pressure switches
1. SlimFit Commercial boilers are equipped with manual reset high gas
pressure and low gas pressure switches (see items 30 and 31, page 3).
2. These switches are factory set and should remain at the following
settings:
a. High gas pressure: 14 inches w.c.
b. Low gas pressure: 2 inches w.c.
3. Note that the low gas pressure switch must be manually reset (button
on front of switch) on initial start-up or any time the gas supply is
turned off.
49
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
SEE 7IRING $IAGRAMS &IGURE &IGURE &IGURE Wire entrances
%,%#42)#!, 3(/#+ (!:!2$ — For your safety, turn off
electrical power supply at service entrance panel before making
any electrical connections to avoid possible electric shock hazard.
Failure to do so can cause severe personal injury or death.
Wire entrances
The installation must comply with National Electrical Code and
any other national, state, provincial or local codes or regulations.
In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any
local codes.
Wiring must be N.E.C. Class 1. If original wiring as supplied with
boiler must be replaced, use only type 105 °C wire or equivalent.
Boiler must be electrically grounded as required by National
Electrical Code ANSI/NFPA 70 – latest edition.
Do not use 24V from transformer to power any external devices
that are not listed in this manual.
Wire entrances
Eight knockouts are provided in the top of the cabinet for line
and low voltage wiring. See Figure 51 for locations.
)NSTALLER -534 USE A STRAIN RELIEF through jacket knockouts.
Failure to do so can cause severe personal injury, death or substantial property damage.
Wiring overview
See details on the following pages for the wiring connections
outlined below:
Required wiring connections
s
120VAC power to boiler; 120VAC power out to boiler circulator; system supply and return temperature sensors.
Connections as needed by systems
s
s
s
s
Thermostat, end switch or other inputs for call for heat.
System zone circulators, valves, relays, etc.
System circulator, when required.
Outdoor temperature sensor.
Optional wiring connections
s
50
External limits; proof-of-closure interlocks (combustion air
damper, flow switch, etc.); 0–10VDC for target or modulation
control; remote alarm; additional heat demand contact; and
communication cables for boiler networking and/or building
management system interface (MODBUS).
Part number 550-100-168/0516
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
A. 120 VAC Power Supply – REQUIRED
4ERMINAL "LOCK (control panel, left side)
1. Boiler line voltage power — Boiler load is 18 amps. Provide and install a
fused disconnect or service switch (25- or 30-ampere rated recommended) as
required by applicable codes.
2. Connect properly sized 6!# power wiring to SlimFit boiler line voltage
terminal strip as shown at right.
3. If possible, provide a surge suppressor in the supply power line. This will reduce
the possibilities of control damage due to line surges.
4. Must wire ground to this terminal to provide boiler grounding.
See Figure 52, page 60 for details
" 6!# /UTPUTS – On each boiler – As needed for systems
4ERMINAL 3TRIP 0 (SlimFit control module, right side)
1.
2.
3.
4.
Output 1: P2 Terminals 1 (H), 4 (N), 7 (G).
Output 2: P2 Terminals 2 (H), 5 (N), 8 (G).
Output 3: P2 Terminals 3 (H), 6 (N), 9 (G).
Maximum load: 2.2 amps (use relay if circulator load is higher). See WARNING below.
5. Each boiler has three outputs (Output 1, Output 2, and Output 3) that provide
120 VAC to the following listed below.
s A zone circulator.
s A system circulator.
s A DHW circulator (used to circulate through an indirect tank).
s An auxiliary item that must be energized during an input call, such as
an air damper.
6. When using inputs/outputs for heat/DHW demands, each input (Input 1,
Input 2, and Input 3) controls its respective 120 VAC output (Output 1,
Output 2, and Output 3). Outputs are energized only when BOTH conditions below are met:
a. The corresponding input indicates a call for heat/DHW (i.e., contact
closure).
b. The PRIORITY assigned to the Input/Output pair is ACTIVE (i.e., the
zone may be calling but the pump won’t activate unless the boiler is currently running on that system/priority).
7. When using the inputs/outputs for the AUX PUMP/OUTPUT function, the
output is controlled by selectable conditions set up in the control.
a. Use the AUX PUMP/OUTPUT function for devices such as system pumps,
combustion air dampers, and other auxiliary equipment to activate when
the boiler is on/running.
b. See page 75 and page 76 for more information on the setup and selection
of operating conditions.
&OR 0RIORITY $(7 !PPLICATION:
The DHW aquastat can be connected to any one of the three input/
output pairs. The selected input should be assigned to PRIORITY 1
during the WIZARD setup or manually in the ASSIGN INPUTS
menu.
#)2#5,!4/2 0/7%2 — 4HE MAXIMUM ALLOW
ABLE CURRENT FOR EACH CIRCULATOR IS AMPS
AT 6!#.
Part number 550-100-168/0516
See Figure 52, page 60 for details
Output circuits are 120 VAC. If an
output is to operate a low voltage circuit or must be an isolated contact,
use an isolation relay. See example
above for 24 VAC zone valves.
For circulators with higher amp ratings, install a circulator
relay or starter. Connect only the 120 VAC coil to the SlimFit
circulator terminals.
51
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
# 6!# TO "OILER #IRCULATOR – REQUIRED
4ERMINAL 3TRIP %0 "/),%2 #)2# (Expansion module, top right)
1.
2.
3.
4.
Provides 120 VAC Dry Contact for boiler circulator.
Terminals are: 1 (H), 2 (H).
Maximum load: 10 amps (use relay if circulator load is higher).
Provide and install a fused disconnect or service switch (15-ampere rated
recommended) as required by applicable codes for circulator with maximum
load of 10 amps.
5. The boiler circulator is used in the boiler loop of the primary / secondary
piping. Primary / secondary piping is recommended to be used with the
SlimFit boiler to ensure proper flow through the heat exchanger.
See Figure 52, page 60 for details
$ 6!# )NPUTS AND TSTATS END SWITCHES ETC – As needed for systems
4ERMINAL 3TRIP 0 INPUT 4ERMINAL 3TRIP 0 INPUTS (SlimFit control module, left side)
1.
2.
3.
4.
Input 1 – Terminal Strip P11 – 4 & 5 (SlimFit control module).
Input 2 – Terminal Strip P15 – 1 & 2 (SlimFit control module).
Input 3 – Terminal Strip P15 – 3 & 4 (SlimFit control module).
These three inputs on each boiler can indicate a call for heat to the control
by means of a dry contact closure (thermostat, aquastat, or switch). (See
right and Figure 52, page 60).
5. The control provides inputs for up to three zones or three systems (priorities).
The control default setting is for three space heating zones tied to
PRIORITY 2, which is defaulted to FINNED TUBE BASEBOARD
system type.
6. For DHW applications, the aquastat can be connected to one of the three
input/output pairs. Take advantage of factory default settings by using PRIORITY 1 for the DHW system. The default control setting for PRIORITY 1
is a direct-piped DHW system type.
7. The default control setting uses each input (INPUT 1, INPUT 2, and INPUT 3) to control its respective 120VAC output (OUTPUT 1, OUTPUT 2,
and OUTPUT 3).
Use of 0–10VDC input for modulation disables Input 1 from creating calls for heat. See page 57 for instructions.
See Figure 52, page 60 for details
An input can be assigned to an AUX PUMP/OUTPUT function to
operate a system pump or interlock with a combustion air damper.
Inputs assigned for this function cannot be used for heat demand
operation. See page 75 and page 76 for more information on the
setup and selection of operating conditions.
52
4HERMOSTATS — $/ ./4 supply 24-volt power to the thermostat
:ONE VALVES — If using 3-wire zone valves, use
circuits (Input1, Input2 and Input3 in Figure 52, page 60) or attempt to supply 24 volts for any other application.
For thermostats that require a continuous 24-volt power source,
connect the common wire (“C”) to 0 Pin 2 (see Figure 52,
page 60). Do NOT exceed total amp draw per thermostat.
relays to provide dry contacts to the Control thermostat connections. The zone valve end switches
of 3-wire valves carry 24 VAC from the valve.
4HERMOSTAT ANTICIPATOR SETTING — 0.1 amps.
Part number 550-100-168/0516
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
% 3YSTEM SUPPLY AND RETURN TEMPERATURE SENSORS – REQUIRED
4ERMINAL "LOCK 0 (SlimFit control module, left side)
1. Two strap-on temperature sensors are shipped with each boiler. Attach one
to the system supply piping and the other to the system return piping. For
piping larger than 5 inch diameter or nonmetallic piping, using immersion
sensors will provide faster response. See SlimFit boiler manual replacement
parts section for available immersion sensors.
2. Locate the supply sensor at least six pipe diameters, but no further than 3
feet, downstream from the boiler connection to the main to ensure adequate
mixing.
3. Supply sensor – wire between P14 #1 and #2 (common).
Strap to supply & return piping
4. Return sensor – wire between P14 #3 and #2 (common).
5. Thermostat wire can be used to connect these sensors.
6. The Control compares the system return temperature with the system supply
temperature. Should the return temperature ever exceed the supply temperature, the Control knows there is likely a sensor failure and will report this
problem on the display.
All heating systems shown in this manual require the System Supply and Return sensors to be installed for proper control function.
System will not properly provide heat if sensors are not installed
according to these instructions.
See Figure 52, page 60 for details
F. Outdoor temperature sensor – OPTIONAL
4ERMINAL "LOCK 0 (SlimFit control module, left side)
1. The control provides programmable options if using an outdoor temperature sensor. This sensor is supplied with the boiler.
2. Mount the outdoor sensor on an exterior wall, shielded from direct sunlight
or flow of heat or cooling from other sources.
3. The wire outlet on the sensor must be oriented DOWN to prevent water
entry.
4. Connect the sensor leads to the terminal shown at right and in the wiring
diagrams (see Figure 52, page 60). Thermostat wire can be used to connect
the sensor.
Part number 550-100-168/0516
See Figure 52, page 60 for details
53
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
G. External limits – OPTIONAL
4O CAUSE MANUAL RESET 4ERMINAL "LOCK 0 (SlimFit control module, left side)
3LIM&IT CONTROL WILL REQUIRE MANUAL RESET AFTER CIRCUIT IS INTERRUPTED
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. The limit must close and the control must be
manually reset using the procedure given in this manual. See drawing at right
and wiring diagram (Figure 52, page 60).
The control will lockout when a limit in its manual reset circuit opens
(P13 pins 1 & 2). The control activates its alarm terminals and shuts
the boiler off. An operator (user or technician) must manually reset
the control to resume heating. Cycling power on and off will NOT
reset the control.
See Figure 52, page 60 for details
4O CAUSE AUTOMATIC RESET 4ERMINAL "LOCK 0 (SlimFit control module, left side)
3LIM&IT CONTROL WILL RESET AUTOMATICALLY AFTER CIRCUIT IS INTERRUPTED
1. Remove factory-installed jumper and connect isolated contacts of external
limits across P13 pins 3 and 4 to cause the control to shut down the burner
on limit opening, then automatically restart 150 seconds after the limit closes.
2. See drawing at right and wiring diagram (Figure 52, page 60).
See Figure 52, page 60 for details
H. Alarm contacts – OPTIONAL
4ERMINAL "LOCK 0 (SlimFit control module, top left)
1. The control’s alarm dry contact (P16, terminals 4 and 5) closes when the
boiler enters manual lockout only.
2. Connect these terminals for remote alarm notification.
3. Contact electrical ratings: 24 VAC or less; 0.5 amp or less.
See Figure 52, page 60 for details
54
Part number 550-100-168/0516
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
I. Proof of closure (flow switch and/or CAD) – OPTIONAL
*UMPER ON 4ERMINAL 3TRIP 0 (SlimFit control, bottom left of center)
1. A flow switch or combustion air damper (CAD) interlock can be configured by clipping the purple wire attached to Pin 3 of P7 such that there is
sufficient room to strip ends and connect to field wiring. Strip the jumper
ends and wire components as shown at right and in the wiring diagram
(Figure 52, page 60).
Do NOT clip wires attached to other pins on P7. Only clip purple
wire attached to PIN 3. Damaging the other wires will cause boiler
fault and will require part repair or replacement.
2. No control settings are required when using a flow switch.
3. Recommended configuration of the SlimFit control for a CAD interlock:
a. Assign ).054 as a !58 05-0 /54054 function.
b. For the !58 05-0/54054 operating mode, select !.9 "52.%2
$%-!.$. This ensures the damper will be activated any time the boiler
is called on to fire.
c. /54054 will provide 120VAC to the damper motor. Use an isolation
relay if damper motor requires another voltage or more than 2.2 amp if
using 120 VAC.
See Figure 52, page 60 for details
* The devices used must provide electrically isolated contacts,
because the P7 jumper circuit carries 5 VDC.
Part number 550-100-168/0516
55
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
J. 0 –10 VDC Remote TARGET input – OPTIONAL
4ERMINAL "LOCK 0 (SlimFit control module, left side)
1. See illustration at right and Figure 52, page 60 (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.
a. The input positive connection must be at P15 terminal 6 and the common
connection at terminal 5.
3. This illustration also shows how to connect TT or end switch contacts at
INPUT 1, INPUT 2 and INPUT 3.
a. If a Heat/DHW demand is required, connect the demand’s dry contact
to an unused input on the control and its pump/valve to the respective
output. Then assign and setup a priority to the input using the Wizard
or manually through the contractor menu.
b. A dry contact heat demand must be applied to one of the inputs in order
to initiate a call for heat.
4. The 0–10VDC signal is used to adjust the supply target temperature, using
the TARGET ADJUST setting. Set TARGET ADJUST during the WIZARD
or manually in the PRIORITY SETTINGS menu for the desired PRIORITY.
a. Many options are available for configuring the control. The following is
a suggested setup that uses factory default settings as much as possible.
b. Use PRIORITY 1 for the DHW heating system when used. This priority’s
default values are set for DHW, direct-piped to the boiler. Verify that settings are suitable for the application, change if needed.
See Figure 52, page 60 for details
c. Use PRIORITY 2 for the heating systems.
s
For single boilers, the factory default settings for PRIORITY 2
make this priority a good choice for space heating applications.
Set PRIORITY 2 values to the following:
s
Set TARGET ADJUST value to 0–10V.
s
Set VOLTS FOR MAX at the voltage that will call for the highest target
temperature. Set SUPPLY MAX at this temperature.
s
Set VOLTS FOR MIN at the voltage that will call for the lowest target
temperature. Set SUPPLY MIN at this temperature.
s
For voltages between VOLTS FOR MAX and VOLTS FOR MIN, the
target temperature will range proportionately between SUPPLY
MAX and SUPPLY MIN. See the SlimFit Advanced Manual for a full
discussion.
NOTE: The 0–10VDC signal replaces the ODT sensor as the target temperature
modifier (TARGET ADJUST setting). The control does not control
target.
56
Part number 550-100-168/0516
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
K. 0–10 VDC Remote MODULATION input – OPTIONAL
4ERMINAL "LOCK 0 (SlimFit control module, left side)
5SING AN EXTERNAL MULTIPLE BOILER CONTROLLER — Remote modula-
tion using an external controller only works with each boiler set up
as a SINGLE boiler in the SlimFit Control setup.
1. See illustration at right and Figure 52, page 60 for details.
2. This illustration also shows how to connect TT or end switch contacts at
INPUT 2 and INPUT 3 for other uses.
3. This function can only be used with a single boiler, NOT for a boiler in a
network.
4. Note that using 0–10VDC input replaces INPUT 1 to generate a heat demand
as shown at right.
5. Remote modulation requires a 0–10VDC input signal at P15-4/5 as shown
at right.
a. The 0–10VDC input positive connection must be at terminal 6 and common connection at terminal 5.
6. Control setup:
a. Many options are available for configuring the control. The following is
a suggested setup that uses factory default settings as much as possible.
b. If DHW is required, use PRIORITY 1 to minimize setup steps.
s Connect the DHW aquastat to INPUT 2 or INPUT 3 and assign the
input used to PRIORITY 1.
s Verify that control settings are suitable for the application, changing
if necessary.
c. Use PRIORITY 2 for the system to be remote modulated.
s The factory default settings for this priority are best suited for space
heating.
s Assign INPUT 1 to the priority chosen. Accept all defaults for INPUT 1
— no changes should be necessary during the WIZARD.
s After the WIZARD has been completed, go to the ASSIGN INPUTS
menu for INPUT 1. Change SOURCE to 0–10V (default setting is TT1).
See page 75 for ASSIGN INPUTS menu information.
7. Operation:
a. A heat demand is activated at 0.9VDC and turns off at 0.8VDC. 2 VDC =
20% input. 10 VDC = 100% input. These voltage settings are not adjustable.
b. OUTPUT 1 (120 VAC) is activated and deactivated as the heat demand is
turned on and off. This output is a good choice to operate the system pump.
8. NOTE: The SlimFit control can be configured to use either 0–10VDC for
target operation (see previous section) or modulation, BUT NOT BOTH.
See Figure 52, page 60 for details
L. 120 VAC Power Receptacle
,OCATED ON BOILER RIGHT SIDE PANEL
1. Electrical rating is 2.0 amps max at 120 VAC.
2. This receptacle can be used to plug in a condensate pump.
Part number 550-100-168/0516
57
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
M. Multiple Boiler and BMS Connections – see ADVANCED Manual
4ERMINAL 3TRIPS 0 AND 0 ON %XPANSION -ODULE (Expansion module, right side)
1. The boiler control is capable of multiple boiler communication and control
of up to eight boilers in one installation.
2. The boiler control is also capable of BMS communication.
3. See SlimFit Advanced Manual for multiple boiler installation and setup
information.
See SlimFit Advanced Manual for details
N. Additional heat demand contacts – OPTIONAL
4ERMINAL "LOCK 0 0INS (SlimFit control module, top left)
1. The control module can be set to activate another heat source using its additional heat demand dry contacts through terminal block P16 pins 6 & 7.
2. Connect these terminals to call for heat from the other heat source.
3. Contact electrical ratings: 24VAC or less; 0.5 amp or less.
4. Set the control to activate the heat demand contacts as needed.
5. See SlimFit Advanced Manual to configure.
See Figure 52, page 60 for details
O. 0-10 VDC Output Section
4ERMINAL "LOCK 0 0INS (SlimFit control module, top left)
1. The control module can be set to activate another heat source using its
0-10VDC Output through terminal block P16 pins 1 & 2.
2. Connect these terminals to 0-10VDC inputs on another heat source to control
its modulation rate.
3. Maximum electrical ratings: 10VDC; 108μ A.
4. Set the control to activate the output as needed.
5. See SlimFit Advanced Manual to configure.
See Figure 52, page 60 for details
58
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Notes
Part number 550-100-168/0516
59
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
&IGURE Schematic wiring diagram — SF-550 & SF-750 (continued on next page)
60
Part number 550-100-168/0516
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
&IGURE (continued from previous page) Schematic wiring diagram — SF-550 & SF-750
Part number 550-100-168/0516
61
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
&IGURE Ladder wiring diagram — SF-550 & SF-750 (continued on next page)
62
Part number 550-100-168/0516
®
SlimFit Series 3
Field wiring
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
SEE &IGURE &IGURE — Boiler Manual
(continued)
&IGURE (continued from previous page) Ladder wiring diagram — SF-550 & SF-750
Part number 550-100-168/0516
63
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Zoning with the SlimFit Control
A. Zoning with CIRCULATORS, suggested applications
Three space heating zones (no DHW)
1. Review wiring information on page 60 (120VAC outputs) 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; and circulator outputs on P2 as shown.
3. The factory default settings assign all inputs 1, 2 and 3
to PRIORITY 2.
4. Choose the space heating system type that matches the
heating system during the WIZARD setup or manually
in the PRIORITY 2 menu.
5. Use the factory default settings for the system type
chosen, or change if needed.
6. Factory defaults should work for other settings not
listed above.
Two space heating zones plus DHW piped
directly to boiler
1. Review wiring information on page 60 (120VAC outputs) and page 52 (24VAC inputs).
2. The configuration at right uses INPUT 2 and 3 for space
heating thermostats. INPUT 1 uses the input from a
DHW aquastat.
3. The factory default settings assign inputs 1, 2 and 3 to
PRIORITY 2. Keep inputs 2 and 3 assigned to PRIORITY 2. To set up PRIORITY 2, choose the space heating
system type that matches the heating system during the
WIZARD setup or manually in the PRIORITY 2 menu.
4. Assign INPUT 1 to PRIORITY 1, which is factory default
configured for DHW applications.
5. Use the factory default settings for DHW and for the
heating system type chosen, or change if needed.
6. Factory defaults should work for other settings not
listed above.
WMCR circulator zone controller plus DHW
controlled by boiler, DHW piped directly to
boiler
1. Review wiring information on page 60 (120VAC outputs) and page 52 (24VAC inputs).
2. To shut down Space Heating during DHW operation:
Provide and connect relay R1 (120VAC coil with NC
contact) to interrupt the Zone controller’s ZC-ZR
(120VAC operating circuit).
3. The configuration at right uses INPUT 2 for space
heating with the call for heat coming from the zone
controller (X-X). INPUT 1 uses the input from a DHW
aquastat.
4. The factory default settings assign inputs 1, 2 and 3 to
PRIORITY 2. Keep input 2 assigned to PRIORITY 2.
To set up PRIORITY 2, choose the space heating system type that matches the heating system during the
WIZARD setup or manually in the PRIORITY 2 menu.
5. Assign INPUT 1 to PRIORITY 1, which is factory default configured for DHW applications. Wire the DHW
circulator to OUTPUT 1.
6. Use the factory default settings for DHW and for the
heating system type chosen, or change if needed. Factory
defaults should work for other settings not listed above.
64
P15, P11 and P2 are terminal strips on the control
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
Zoning with the SlimFit Control
— Boiler Manual
(continued)
B. Zoning with ZONE VALVES, suggested applications
Two space heating zones (no DHW)
1. Review wiring information on page 60 (120VAC
outputs) and page 52 (24VAC inputs).
2. The configuration at right uses INPUT 2 and 3 for
space heating thermostats. INPUT 1 is reserved
here for configuring the operation of the system
circulator.
3. The factory default settings assign inputs 1, 2 and 3
to PRIORITY 2. Keep inputs 2 and 3 assigned to
PRIORITY 2. To set up PRIORITY 2, choose the
space heating system type that matches the heating
system during the WIZARD setup or manually in
the PRIORITY 2 menu.
4. Use the factory default settings for the heating system type chosen, or change if needed.
5. Assign INPUT 1 to AUX PUMP/OUTPUT. Then
select ANY INPUT BY ITS PRIORITY when
prompted for when to activate the output. This will
cause the system pump to run when either of the
zones calls for heat. Confirm that Priority 2 RUN
AUX PUMP/OUT is set to YES.
6. INPUT 1 (P11-4/5) cannot be used for a wired connection (as shown at right) because it is being used
in the control setup to run the system circulator.
7. Factory defaults should work for other settings not
listed above.
The system must be equipped with a by-pass
pressure regulating valve. Flow can occur
with zone valves closed.
WMZV zone valve zone controller plus
DHW controlled by boiler, DHW piped
directly to boiler
1. Review wiring information on page 60 (120VAC
outputs) and page 52 (24VAC inputs).
2. The configuration at right uses INPUT 2 for space
heating with the call for heat coming from the zone
controller (X-X). INPUT 1 uses the input from a
DHW aquastat.
3. The factory default settings assign inputs 1, 2
and 3 to PRIORITY 2. Keep input 2 assigned to
PRIORITY 2. To set up PRIORITY 2, choose the
space heating system type that matches the heating
system during the WIZARD setup or manually in
the PRIORITY 2 menu.
4. The system circulator, wired to OUTPUT 2, will
turn on whenever there is a call for heat from the
zone controller.
5. Assign INPUT 1 to PRIORITY 1, which is factory
default configured for DHW applications. Wire the
DHW circulator to OUTPUT 1.
6. Use the factory default settings for DHW and
for the heating system type chosen, or change if
needed. Factory defaults should work for other
settings not listed above.
Part number 550-100-168/0516
P15, P11 and P2 are terminal strips on the control
65
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Control operation and setup
Control setup
1. Set control parameters using the WIZARD option provided on initial
start-up or manually enter parameters using control menus (see
Figure 61, page 72 and following pages for information.)
2. See instructions beginning on page 67 for basic systems and minimum settings required (using factory defaults).
3. This manual provides set-up information for a single boiler using BASIC control setting options. See the SlimFit Advanced Manual for single-boiler advanced settings and for all multiple boiler applications.
&IGURE Control sequence of operation
$ISPLAY
STATUS
TEXT
0/7%2
50
"OILER -ODEL !LTITUDE ARE CRITICAL SETTINGS Failure to set correctly
could result in severe personal injury, death or substantial property
damage.
3TANDBY
4EMPERATURE SETTINGS — You must ensure that the Control is set for
the proper water temperatures for the system. Excessive water temperature can cause significant property damage in some applications.
-ULTI TEMPERATURE SYSTEMS — If the heating system includes circuits
that require lower temperature water (radiant slab circuits, for example)
as well as higher temperature circuits (DHW, finned tube baseboard,
etc.), it is recommended to protect low-temperature circuits with limit
controls that are wired to an Control external limit circuit. Failure to
provide regulation can result in substantial property damage.
Control features
❏ Single or multiple boiler control (with lead boiler rotation).
❏ Graphic and robust text display for ease of operation monitoring and
troubleshooting.
❏ Three programmable priority assignments for up to three heat inputs.
❏ Preset operating parameters for typical heating systems, including target
temperatures, reset curves and circulator assignments.
❏ Integral outdoor reset option, with reset curves matched to the system
type selected.
❏ ModBus communications for external communication and monitoring.
❏ 0-10VDC input modulation or remote target input.
❏ Four pump outputs, 3 – powered, 1– dry contact.
❏ Additional heat demand operation to call a second heat source to help
supply the energy required for heating.
❏ Advanced PI response to anticipate system needs.
❏ Flue temperature modifier to target temperature.
❏ Modulation based on flue sensor and boiler/system supply/return
sensors.
❏ Dual temperature sensors on boiler outlet and flue, providing redundant protection.
❏ Boiler is shipped with an outdoor sensor and strap on system supply
and return sensors.
❏ Blower speed modulation to control boiler firing rate.
❏ Alarm relay on error/fault for use with an audible safety.
❏ CSD-1 Valve set leakage test feature (See Advanced Manual).
❏ Built-in 0–10 VDC signal generator to allow parallel modulation of
multiple boilers; also capable of accepting 0–10 VDC input.
❏ The boiler is equipped with a low water cutoff, factory wired to the
Control, manually reset through the Control.
Sequence of operation
1. Figure 54 is a summary of the operating sequence for the Control.
s The statuses shown appear in the display as the Control cycles the
boiler. See Figure 58, page 70 for screen shots.
s The display will flash red if a problem has been detected.
66
"LOWER
/.
)GNITION
3PACE
(EATING
$(7
(EATING
"LOWER
/&&
#ONTROL ACTION
(Also see Figure 58, page 70)
s Check the boiler model listed on the power-up
screen. If it is not correct, turn off the boiler. See
page 73 for instructions to change setting.
s When power is turned on, the screen lists sensors
that are detected. If any sensor is not listed, make
sure it is connected correctly. Turn off power and
restart.
s Standby - no calls for heat.
s Toggles through no dots, 1 dot, 2 dots, then 3 dots
while in standby (wrench symbol will show instead
if maintenance is needed).
s Call for heat detected.
s Display on with BLUE light (space heating) or
PURPLE light (DHW).
s Start min/max timers if more than one system is
calling - highest priority starts first.
s Start circulators for this priority setup based upon
settings.
s Calculate target temp — If sensor temp is below
target temp, begin firing sequence.
s Blower to ignition speed for prepurge.
s
s
s
s
After prepurge times out, begin ignition cycle.
Activate gas valve and ignition spark.
Continue ignition spark for ignition period.
Turn off spark and use electrode to check for
flame signal.
s Flame detected.
s Release boiler to modulation.
s NOTE: If flame is not detected, the gas valve is
turned off, blower turns on (postpurge), and control starts cycle again. After 5 failures, the control
waits 60 minutes, then tries again.
s If priority timer times out, switch to next priority
and start priority timer.
s If demand satisfied, go to postpurge.
s Flame detected.
s Release boiler to modulation.
s NOTE: If flame is not detected, the gas valve is
turned off, blower turns on (postpurge), and control starts cycle again. After 5 failures, the control
waits 60 minutes, then tries again.
s If priority timer times out, switch to next priority
and start priority timer.
s If demand satisfied, go to postpurge.
s Demand satisfied (temperature reaches target
temperature or limit setting).
s Gas valve off.
s Blower to ignition speed for postpurge.
s Return to standby after purge.
s Display turns BLUE, toggling between graphic
screen and maintenance screen (occurs if maintenance schedule timer times out).
-AINTENANCE s Will show during standby only.
s Boiler operates as normal.
%RRORFAULT
773$
s Display turns RED due to error or limit event.
s Flashing display means lockout condition.
s Warm weather shut down - the boiler will not
be allowed to fire on space heating if the outside
temperature is greater than the WWSD setting.
s DHW operation is not affected by WWSD.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Control operation and setup (continued)
Control Priorities & Input/Outputs
s
s
s
s
s
s
s
Each PRIORITY has its own set of operating parameters. The
control prompts the user to select the system type (finned tube
baseboard, DHW, etc.) and is factory programmed with parameters suited to each of these system types. The user can also choose
CUSTOM to create a system type.
The Control provides up to three priorities for single boiler
applications and up to four priorities for network boiler applications. The order of operation is: PRIORITY 1, PRIORITY
2, PRIORITY 3.
The 120VAC power output to the boiler circulator is provided by
a relay located on the boiler’s Pump/Communications Board. For
each of the priorities, the control can be setup to run the boiler
pump or to leave it off. It is recommended to set Blr Circ to OFF
for DHW that is directly piped with its own DHW Circ.
Each boiler has three input/output pairs (INPUT/OUTPUT 1,
2 and 3. Control setup prompts the user to assign each of these
I/O pairs to a PRIORITY. The Control then knows which system
(priority) to operate when the input receives a call for heat. On
a call for heat to an input, the Control closes the corresponding
output (120VAC) and begins controlling the boilers according
to the setup for the assigned priority.
The MAX ON TIME setting controls the maximum time a priority will be allowed to run before switching to a lower priority’s call
for heat. The MIN ON TIME setting controls the minimum time
a priority will be operated before switching to a higher priority’s
call for heat, or the next lower priority.
The control responds to signals from:
s Room thermostats.
s DHW aquastats (if used).
s Temperature sensors (boiler return, boiler supply, flue
temperature) and, when used, system supply and system
return, outdoor temperature). &OR OPTIMAL PERFORMANCE IT
IS RECOMMENDED TO INSTALL THE SYSTEM SUPPLY AND RETURN
SENSORS
s
The control automatically adjusts blower speed (and gas flow
rate) to match boiler output to space heating and/or DHW
heating demand.
s
The control provides three inputs and three outputs (for circulators or auxiliary devices) plus a fourth boiler circulator output.
s
The outdoor temperature is used for supply temperature reset
operation and for the warm weather shut down (WWSD) option.
s
Step 1
s $%4%2-).% INPUTOUTPUT NEEDS n
s 7HAT ARE THE INPUTS n 4HERMOSTATS REMOTE CONTACTS END
SWITCHES ETC
s 7HAT DOES EACH CONTROLS OUTPUT NEED TO DO n OPERATE A
PUMP ACTIVATE AN AIR LOUVER ETC
Step 2
s #ONNECT WIRING TO THE CONTROL INPUTS AND OUTPUTS TO
ACCOMPLISH THE PURPOSES SET IN 3TEP Step 3
s )NSTALL THE BOILER FOLLOWING ALL INSTRUCTIONS IN THE 3LIM&IT
"OILER -ANUAL BEFORE PROCEEDING FURTHER
s 3EE THE !DVANCED -ANUAL FOR MULTIPLE BOILER INSTALLATIONS
s &OLLOW INSTRUCTIONS IN THE "OILER -ANUAL TO START UP AND
POWER THE BOILER
Step 4
s 5SE THE 7):!2$ BELOW OR ENTER CONTROL PARAMETERS
MANUALLY SKIP 7IZARD Control WIZARD
s
s
s
The Wizard is available on initial setup of the boiler. It leads
through a step-by-step setup procedure designed for the
application chosen.
Context-sensitive help is available to explain the purpose
of key setup items.
Advanced settings for single boiler applications can be accessed manually from the Contractor menu.
WIZARD Sequence
Boiler
Settings
s !LTITUDE n
n MUST BE SET CORRECTLY FOR PROPER
OPERATION
s 773$ n SET OUTDOOR TEMPERATURE ABOVE WHICH SPACE
HEATING WILL BE DEACTIVATED
s &UEL NATURAL GAS OR PROPANE n
n MUST BE SET
CORRECTLY FOR PROPER OPERATION n CONTROL WILL PAUSE UNTIL THIS
VALUE TO SELECTED
Inputs/
Outputs
s 3ELECT THE USAGE OF INPUTS AND s $ETERMINE USAGE OF OUTPUTS AND OUTPUTS CORRESPOND
TO INPUTS Set
Priorities
s !SSIGN PRIORITIES AND TO THE INPUTS
System
Settings
s 3ET SYSTEM SETTINGS OR LEAVE AT THEIR DEFAULTS
System
Types
s 3PECIFY WHAT SYSTEM TYPE IS CONNECTED TO EACH OF THE THREE
OUTPUTS EACH SYSTEM TYPE CAUSES THE CONTROL TO PRESET
OPERATING TEMPERATURES
When multiple inputs are set up on the same priority, they will
run at the same time if the priority and inputs are active.
Control operation
s
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 and minimum times a system will be operated before being
turned off to allow another system to operate. A typical example
is DHW priority — heat demand from the DHW system is given
preference over space heating, if set to use Priority 1.
System presets:
s The Control provides presets by system type (see Figure 59, page 71 for complete list).
Part number 550-100-168/0516
Output
Activation
s 7HEN APPLICABLE 3ELECT WHEN TO ACTIVATE !58 05-0
/54054 n BY INPUT ALWAYS ON EXTERNAL SWITCH ETC
Priority
Switching
s 3ET MAXIMUM AND MINIMUM TIMINGS FOR PRIORITIES
Date/Time
s 3ET DATE AND TIME n IMPORTANT FOR CONTROL DIAGNOSTIC LOGGING
Information
s 3ET INSTALLER NAME AND CONTACT INFORMATION
s %NTER #0 INSTALL DATE MAINTENANCE DATE ETC
s 3ET AUTOMATIC MAINTENANCE NOTIlCATION TIMING
67
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Control operation and setup (continued)
Outdoor reset operation
&IGURE 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.
3. The temperature settings discussed below are accessed in the
priority menu for the applicable system. For detailed explanations
of the priority menus, see Figure 63, page 74.
SUPPLY MAX
1. Set Supply max to the required supply water temperature for the
system at design maximum heat loss (typically 180°F for finned
tube baseboard on new installations).
SUPPLY MIN
1. Supply min should equal the desired minimum supply water
temperature for the system.
2. This could be set as low as 70°F, which would supply “zero heat”
when outdoor temperature is 70°F, because supply water temperature would equal room temperature.
3. See examples in Figure 55.
OD RESET MAX
&IGURE Remote target operation
1. OD RESET MAX means the outdoor temperature at which the
target temperature reaches its minimum (Supply min).
2. In the examples of Figure 55, this occurs at 70 °F (the factory
default).
OD RESET MIN
1. OD RESET MIN means the outdoor temperature at which the
target temperature reaches its maximum value (Supply max).
2. In the examples of Figure 55, this occurs at 0°F outside (the factory default setting).
3. OD RESET MIN should equal the ODT (outdoor design temperature) for the installation’s location.
Remote target operation (0–10VDC input)
1. This function allows a remote analog input to regulate the supply temperature for control operation/modulation. This can be
done for any priority, including network and local priorities for
multiple boiler networks.
2. The settings discussed below are accessed in the priority menu
for the applicable system. For detailed explanations of the priority
menus, see Figure 63, page 74.
3. See Figure 56 for an explanation of target temperature vs voltage
when using remote target operation.
4. In the priority menu for the applicable system, select 0-10v for
the TARGET ADJUST setting.
5. In the same priority menu, select the VOLTS FOR MIN and VOLTS
FOR MAX values. VOLTS FOR MIN sets the voltage value for the
desired minimum supply temperature. VOLTS FOR MAX sets
the voltage value for the desired maximum supply temperature.
68
Remote modulation operation
(0–10v input)
1. To use 0-10VDC for remote modulation, go to Contractor Menu -> Assign Inputs. Then change Input 1’s
source to 0-10V. The priority that is assigned to Input
1 cannot be used by any other Input.
2. The boiler comes on at 0.9VDC and turns off at 0.8VDC.
2 VDC = 20% input. 10 VDC = 100% input. These voltage settings are not adjustable.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Control operation and setup (continued)
&IGURE SlimFit single boiler essential settings (2%15)2%$ on initial start-up) — see page 71 for explanation
Part number 550-100-168/0516
69
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Control operation and setup (continued)
&IGURE SlimFit control display screens and typical navigation
70
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Control operation and setup (continued)
&IGURE SlimFit control settings available in BASIC MODE (see Advanced Manual for ADVANCED MODE settings)
!VAILABLE SETTINGS FROM #/.42!#4/2 -%.5
"OILER 3ETTINGS -ENU
0RIORITY MENU
!SSIGN )NPUTS MENU
s Boiler Model
s Inputs Assigned (non-selectable)
)NPUT 44
s Control Type
s System Type
s Priority 1, 2 or 3
s High Altitude
s Target Mod Sensor (non-selectable)
s Source (TT1 or 0-10v)
s LP Gas
s Target Adjust (non-selectable)
s AUX PUMP/OUTPUT
s Manual Reset High Limit Temp
s Supply Max
s Off
s WWSD Temp
s Supply Min (not available for DHW) *
s Adjust Outdoor
s OD Reset Max (or Volts for Max) *
)NPUT 44
s Circulator Exercising
s OD Reset Min (or Volts for Min) *
s Priority 1, 2 or 3
s Freeze Protect Circs
s Boost Time *
s AUX PUMP/OUTPUT
s Reset Factory Default
AND
)NPUT 44
s Off
0RIORITY MENU
s Inputs Assigned (non-selectable)
$IAGNOSTICS MENU
0RIORITY MENU
s System Type
s See Figure 67, page 77 for details.
s Inputs Assigned (non-selectable)
s Target Mod Sensor (non-selectable)
s System Type
s Target Adjust (non-selectable)
-AINTENANCE )NFO MENU
s Target Mod Sensor (non-selectable)
s Supply Max
s See Figure 72, page 82 for details.
s Target Adjust (non-selectable)
s Supply Min (not available for DHW) *
s Supply Max
s OD Reset Max (or Volts for Max) *
3ET $ATE AND 4IME MENU
s Supply Min (not available for DHW) *
s OD Reset Min (or Volts for Min) *
s See Figure 72, page 82 for details.
s OD Reset Max (or Volts for Max) *
s Boost Time *
s OD Reset Min (or Volts for Min) *
* These items only appear in the menus if Target Adjust is active.
s Boost Time *
&IGURE System types available in BASIC MODE (each option shown with factory settings)
3YSTEM 4YPE
8-Character
Abbreviation
3-Character
Abbreviation
Supply Max
°F
OD Reset
Min °F
Supply
Min °F
OD Reset
Max °F
Run
Boiler Pump
Run AUX
PUMP/
OUTPUT
Fan-coil
FAN-COIL
FCL
180
0
140
70
YES
YES
Finned Tube Baseboard
FIN BASE
FTB
180
0
130
70
YES
YES
Cast Iron Baseboard
IRONBASE
CIB
180
0
120
70
YES
YES
Cast Iron Radiators
RADIATOR
CIR
180
0
120
70
YES
YES
Radiant - slab on grade
RAD SLAB
RSG
120
0
80
70
YES
YES
Radiant - thin slab
RAD SLAB
RTS
140
0
80
70
YES
YES
Radiant - below floor
(staple up)
RADFLOOR
RSU
160
0
90
70
YES
YES
Radiant - above floor
(sleeper system)
RADFLOOR
RAF
140
0
90
70
YES
YES
Domestic Hot Water
DOMESTIC
DHW
180
N/A
N/A
N/A
NO
NO
Custom (user defined)
XXXXXXXX
(user input)
first three of
user input
180
0
70
70
YES
YES
Part number 550-100-168/0516
71
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
CONTRACTOR menus
"OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITI
CAL SETTINGS Failure to set correctly could result in
severe personal injury, death or substantial property
damage.
1. Access contractor menus by pressing and holding the UP and
DOWN arrow keys at the same time for 7 seconds.
2. See the following pages for explanations of control setting
options.
&IGURE SlimFit control menu access — accessing contractor menus
-ORE
INFORMATION
-%.5 )4%-
0520/3%
USER MODE
s The default for this setting is "!3)# mode. Screens shown
in this manual assume the USER MODE is set to BASIC. For
advanced features available in !$6!.#%$ mode, see the
SlimFit Advanced Manual.
BOILER
SETTINGS
s Set/change boiler model, control type,
high altitude setting, ODT sensor requirement, manual reset, high limit and WWSD
temperature settings, outdoor sensor temp
adjustment, circulator exercising, freeze
protection setup, and restore to factory
default option.
See page 73
PRIORITY 1
s These settings control operating temperatures and behaviors for systems that are
assigned to “PRIORITY 1.”
See page 74
PRIORITY 2
s These settings control operating temperatures and behaviors for systems that are
assigned to “PRIORITY 2.”
See page 74
PRIORITY 3
s These settings control operating temperatures and behaviors for systems that are
assigned to “PRIORITY 3.”
See page 74
ASSIGN INPUTS
s These settings assign Priority 1, 2 or 3 to
each of the three inputs to the control.
See page 75
DIAGNOSTICS
s Use to review current and historical information including previous lockouts.
See page 77
MAINTENANCE
INFO
s Used to set contractor contact information,
boiler information and maintenance dates.
See page 82
SET TIME &
DATE
s Use to set date and time — important since
fault occurrences are date/time stamped.
None
Screens shown above are typical
only. Actual screens depend on
control settings chosen.
72
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
BOILER SETTINGS menu, BASIC mode
"OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITI
CAL SETTINGS Failure to set correctly could result in
severe personal injury, death or substantial property
damage.
1. Access contractor menus by pressing and holding the UP and
DOWN arrow keys at the same time for 7 seconds.
2. See Figure 61, page 72 for the screen sequences up to the
CONTRACTOR menu.
&IGURE SlimFit BASIC mode BOILER SETTINGS options (USER MODE must be set to BASIC)
-%.5 )4%-
$%3#2)04)/.
"/),%2 -/$%,
s
MUST be set to correct model.
s Check the boiler model against the model listed on the
boiler’s rating plate. Change the selection to the correct
model if not. Also verify the model number on the control display at power-up. Failure to correct would result
in severe personal injury, death or substantial property
damage.
#/.42/, 490%
s Select single, master or shadow. Must be set to Single for
basic mode.
s
()'( !,4)45$%
If the boiler is installed at an altitude above 5500
feet, select YES for high altitude. The control will automatically adjust firing rates (blower speeds) to compensate for
altitude. Altitude MUST be set correctly to avoid risk of severe personal injury, death or substantial property damage.
-!.5!, 2%3%4
()'( ,)-)4 4%-0
s If boiler outlet water temperature exceeds this temperature, the Control will shut down the boiler and enter
lockout. Changing this setting is NOT recommended.
773$ 4%-0
s WWSD stands for warm weather shut down. It
means the boiler will not be allowed to fire if the outside temperature is greater than the WWSD setting.
When the boiler is kept off because the outside temperature is above WWSD, the graphic display will show
WWSD, and the boiler will remain in standby until the
outside temperature drops below WWSD temperature.
WWSD does not apply to DHW systems.
The outdoor sensor must be installed to use this function.
!$*534 /54$//2
s Use this setting to calibrate the outdoor sensor when needed
to compensate for variations in lead length or other factors
that could affect total resistance in sensor circuit.
#)2#5,!4/2
%8%2#)3).'
s For each circulator, select whether you want the control
to automatically start the circulator and run for 10 seconds for each 72-hour period of inactivity.
&2%%:% 02/4%#4
#)2#3
s This function automatically fires the boiler at low fire and
starts the circulators chosen if the heat exchanger sensors
detect a temperature less than 45 °F. Burner is turned on
if temperature drops below 40 °F. Circulators and burner
turn off when the temperature rises above 48 °F.
2%3%4 &!#4/29
$%&!5,43
s Use this function to restore all control settings to factory
default values — will require complete restart and setup
of control after resetting. Record information from
the MAINTENANCE screen and any history information that may be of use in the future. ALL stored data is
eliminated when reset to defaults except for boiler model
number.
Screens shown above are typical
only. Actual screens depend on
control settings chosen.
Part number 550-100-168/0516
73
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
PRIORITY 1, 2, 3 menus, BASIC mode
"OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITI
CAL SETTINGS Failure to set correctly could result in
severe personal injury, death or substantial property
damage.
1. Access contractor menus by pressing and holding the UP and
DOWN arrow keys at the same time for 7 seconds.
2. See Figure 61, page 72 for the screen sequences up to the
CONTRACTOR menu.
&IGURE SlimFit BASIC mode PRIORITY options (USER MODE must be set to BASIC)
-%.5 )4%-
Screens shown above are typical
only. Actual screens depend on
control settings chosen.
74
$%3#2)04)/.
s Lists all the inputs already assigned to this PRIORITY.
Inputs will be listed as 1, 2, 3.
INPUTS ASSIGNED
s Shows NONE if there are no inputs assigned to this
priority .
s Select the system type for this PRIORITY, based
on the heating terminal units in the system (see
Figure 59, page 71). Use the CUSTOM selection to set
the control for a different system type. The factory preset
SYSTEM TYPE
values for SUPPLY MAX, SUPPLY MIN, OD RESET MAX
and OD RESET MIN are chosen based on the normal best
setting for the terminal units.
s Choose SYSTEM SUPPLY or BOILER OUT to determine
which will be the primary temperature sensor. The control
will modulate boiler input to reach the TARGET temperature. (Default is System Supply.) If system sensors are not
TARGET MOD
used, boiler defaults to using heat exchanger outlet sensor
SENSOR
in place of system sensor.
s Not adjustable in Basic Mode, see Advanced Manual for
information on adjusting this parameter.
s Select how target temperature is calculated by control:
NONE (no reset, fixed target temperature), 0-10V (target
temperature based on analog input from remote source),
TARGET ADJUST
ODT (outdoor reset operation; default setting).
s Not adjustable in Basic Mode, see Advanced Manual for
information on adjusting this parameter.
s Set SUPPLY MAX to the required supply water temperature for the system at design maximum heat loss (typically
SUPPLY MAX
180 °F for finned tube baseboard on new installations.)
s SUPPLY MIN should equal the desired minimum supply
water temperature for the system.
s
This line is not shown on priorities configured as DHW
SUPPLY MIN
system type or Heating system type, if outdoor temperature sensor not used. See Advanced Manual for information on adjusting this parameter .
s OD RESET MAX is the outdoor temperature at which the
target temperature reaches its minimum (SUPPLY MIN).
s
This line is not shown on priorities configured as DHW
OD RESET MAX
system type or Heating system type, if outdoor temperature sensor not used. See Advanced Manual for information on adjusting this parameter .
s OD RESET MIN means the outdoor temperature at
which the target temperature reaches its maximum value
(SUPPLY MAX).
OD RESET MIN
s OD RESET MIN should equal the ODT (outdoor design
temperature) for the installation’s location.
s This line is not shown on priorities configured as DHW
system type or Heating system type, if outdoor temperature sensor not used. See Advanced Manual for information on adjusting this parameter .
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
ASSIGN INPUTS menu, BASIC mode
"OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITI
CAL SETTINGS Failure to set correctly could result in
severe personal injury, death or substantial property
damage.
1. Access contractor menus by pressing and holding the UP and
DOWN arrow keys at the same time for 7 seconds.
2. See Figure 61, page 72 for the screen sequences up to the
CONTRACTOR menu.
&IGURE SlimFit BASIC mode ASSIGN INPUT options (USER MODE must be set to BASIC) — see Figure 65, page 76
and Figure 66, page 76 for explanation of AUX PUMP/OUTPUT settings
-%.5 )4%-
$%3#2)04)/.
Overview
s There are three priority levels defined by the settings
chosen in Figure 63, page 74.
s For DHW priority, make sure PRIORITY 1 is defined
for a DHW system.
s If DHW priority is required and analog input is used
for space heating, assign INPUT 2 to the DHW aquastat (TT2) and INPUT 1 as PRIORITY 2 and SOURCE
set to 0-10V.
s
s
s
s
s
s
s
Assign priority (system type) for INPUT 1 — options are:
PRIORITY 1 — assigns INPUT 1 to PRIORITY 1 system.
PRIORITY 2 — assigns INPUT 1 to PRIORITY 2 system
PRIORITY 3 — assigns INPUT 1 to PRIORITY 3 system
AUX PUMP/OUTPUT
OFF
NOTE: For INPUT 1 only, select SOURCE = TT1 for
thermostat input or 0-10V if analog input is required.
INPUT 2
s
s
s
s
s
s
Assign priority (system type) for INPUT 2 — options are:
PRIORITY 1 — assigns INPUT 2 to PRIORITY 1 system.
PRIORITY 2 — assigns INPUT 2 to PRIORITY 2 system
PRIORITY 3 — assigns INPUT 2 to PRIORITY 3 system
AUX PUMP/OUTPUT
OFF
INPUT 3
s
s
s
s
s
s
Assign priority (system type) for INPUT 3 — options are:
PRIORITY 1 — assigns INPUT 3 to PRIORITY 1 system.
PRIORITY 2 — assigns INPUT 3 to PRIORITY 2 system
PRIORITY 3 — assigns INPUT 3 to PRIORITY 3 system
AUX PUMP/OUTPUT
OFF
INPUT 1
Screens shown above are typical
only. Actual screens depend on
control settings chosen.
Part number 550-100-168/0516
75
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
ASSIGN INPUTS menu, BASIC mode (continued)
&IGURE AUX PUMP/OUTPUT operation (accessed in ASSIGN INPUTS menu – see Figure 64, page 75)
/PTION
!CTIVATION CONDITIONS
3UGGESTED USES
s Hot loop for seasonal boilers that are manually
shut down at end of season and started up at
start of heating season.
s Hot loop for boilers whose CH is manually
The output is energized on closure of an external switch wired to this
shut down at end of season and started up at
input and is de-energized when the external switch opens.
start of heating season, but remain available for
local calls (DHW, etc.).
This output is energized only when outdoor temperature is below the
WWSD setting (see BOILER SETTINGS menu, Figure 62, page 73). s Hot loop for boilers whose CH is automatically shut down based on outdoor temperature
This setting is non-selectable if WWSD is set to OFF or ODT is not
(inferred heat loss), but remain on for local
connected at initial boiler power. If Outdoor Below WWSD is already
calls (DHW, etc.).
chosen and WWSD is later set to OFF, Outdoor Below WWSD will
behave as Always On.
The assigned output is energized if there is an input closure on this boiler.
The assigned output will de-energize once there are; no input on this
s Energize a system pump relay if pump must
boiler, post-purge has finished, and post-pump time has expired.
run during all heating calls.
If the closed input is configured for a heat demand, its output will deenergize after post-purge and post-pump.
The assigned output is energized:
s If there is an input closure on this boiler.
. . . AND . . .
s Energize a system pump relay if pump must
s RUN AUX PUMP/OUTPUT is set to YES for the priority asrun only on some heat calls (such as systems
signed to the closed input.
with locally-connected DHW heating).
The assigned output will de-energize once there are; no input closures
on any of the network boilers, post-purge has finished, and post-pump
time has expired.
The assigned output is energized when the boiler receives a call for
heat and starts to pre-purge.
s Use for interlocking with combustion air
damper, flow switch, etc.
The assigned output is de-energized once the burner is off and postpurge is complete.
!,7!93 /.
s Output is always energized whenever the control is powered.
%84%2.!,
37)4#(
s
s
/54$//2
"%,/7 773$
s
s
s
!.9 44 ).054
s
s
!.9 44 ).054
"9 )43 02)/2)49
3%44).'3
s
s
"52.%2
$%-!.$
s
&IGURE AUX PUMP/OUTPUT operation — start, run and stop, based on boiler status
/PTION
Standby
!.9 44 ).054
/2
!.9 44 ).054 "9 )43
02)/2)49 3%44).'3
off
"52.%2 $%-!.$
off
76
TT
PrePre-Pump
Closed
Purge
Burner
Running
PostPurge
PostPump
ON
off
off
ON
off
Standby
#OMMENTS
off
s See Figure 65 for explanation of
differences between the ANY TT
INPUT options.
off
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIAGNOSTIC menu
&IGURE $)!'./34)#3 menu navigation (see Figure 58, page 70 for access information)
-ENUS
.EXT SCREEN
.EXT SCREEN
.EXT SCREEN
.EXT SCREEN
Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data
DIAGNOSTICS
TEMPERATURES
INPUTS
OUTPUTS
RUNTIME
STATUS:
##########
BOILER OUT1:
### ºF
BOILER OUT2:
### ºF
HEAT EXCHANGER 1:
### ºF
HEAT EXCHANGER 2:
### ºF
BOILER IN:
### ºF
SYSTEM SUPPLY:
### ºF
SYSTEM RETURN:
### ºF
FROM SENSOR:
######
FLUE 1:
### ºF
FLUE 2:
### ºF
OUTDOOR TEMP:
### ºF
FROM SENSOR:
######
See following pages for details.
STATUS:
##########
INPUT1:
######## (8-character system type)
INPUT2:
######## (8-character system type)
INPUT3:
######## (8-character system type)
0–10V INPUT:
##. #V
LINKED TO MASTER:
###
DEMAND OF MASTER:
###
MANUAL LIMIT:
######
AUTO LIMIT:
######
LOW WTR CUTOFF:
######
AIR P-SWITCH:
######
GAS P-SWITCH:
######
CLOSURE SWITCH:
######
BLOWER SPEED:
####RPM
FLAME SIGNAL:
###
See following pages for details.
STATUS:
##########
GAS VALVE:
###
CIRC OUTPUT 1:
###
CIRC OUTPUT 2:
###
CIRC OUTPUT 3:
###
BOILER CIRC:
###
BLOWER SIGNAL:
###%
ADD’L HEAT DEMANDS:
###
ALARM:
###
0–10V OUTPUT:
##. #V
See following pages for details.
BURNER TIME:
###HR
ROTATE TIME:
###DAYS
INPUT1 TIME:
###HR
INPUT2 TIME:
###HR
INPUT3 TIME:
###HR
NETWORK TIME:
See following pages for details.
###HR
IGNITION COUNT:
MASTER-SHADOW COMM
Boiler ID:
(shows on shadow boilers only)
Linked to Master: ###
###
############
Boilers on Network: #
Requested to Run:
Type:
###
######-##
See following pages for details.
Requested Mod Rate:
Max Boiler Temp:
Boiler ON Diff:
Boiler OFF Diff:
NETWORK BOILERS
(shows on master boilers only)
Part number 550-100-168/0516
###
### ºF
## ºF
## ºF
Shows firing rate, boiler temperature, active priority,
with system type and sequence order of all boilers on the
network.
See following pages for details.
77
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIAGNOSTICS menu (continued)
&IGURE $)!'./34)#3 menu navigation, continued (see Figure 58, page 70 for access information)
-ENUS
.EXT SCREEN
.EXT SCREEN
.EXT SCREEN
.EXT SCREEN
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.
(shows on master boilers only)
SOFTWARE VERSIONS
PAST ERRORS
DISPLAY
WM#.##
MAIN MICRO
WM#.##
SECOND MICRO
WM#.##
CONTROL FAULTS:
###
IGNITION RETRIES:
###
MANUAL RESET CNT:
AUTO RESET CNT:
###
###
See following pages for details.
See following pages for details.
See following pages for details.
See following pages for details.
LOCKOUT HISTORY 1
LOCKOUT HISTORY #
LOCKOUT HISTORY 2
FAULT NAME:
LOCKOUT HISTORY 3
FAULT TYPE:
####
####
TIME:
HH:MM AM
DATE:
MM/DD/YY
STATUS:
########
TEMPERATURES
INPUT STATUS
OUTPUT STATUS
TEMPERATURES
INPUTS
OUTPUTS
MANUAL TEST MODE
(Single boiler or network
Shadow boiler)
STATUS:
########
HEAT EXCHANGER:
####
### ºF or “%” for network
TARGET:
MODULATION:
BOILER IN:
########
### ºF
BOILER OUT:
### ºF
### ºF
SYSTEM SUPPLY:
### ºF
SYSTEM RETURN:
FLUE:
### ºF
OUTDOOR:
### ºF
BLOWER SIGNAL:
###%
BLOWER SPEED:
###RPM
FLAME SIGNAL:
FORCE RATE:
MANUAL RESET
78
See following pages for details.
###
AUTO
PRESS ENTER TO RESET THE FOLLOWING
ERROR (SCREEN SHOWS A LIST OF ERRORS)
See following pages for details.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIAGNOSTICS menu (continued)
&IGURE $)!'./34)#3 menu details (see Figure 58, page 70 for access information)
-ENU)TEM
#OMMENT
4EMPERATURES
3TATUS
Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfied, post purge, Warm Weather
Shut down, Trouble
"OILER /UT
Temperature of the first sensing element of the boiler’s heat exchanger outlet sensor
"OILER /UT
Temperature of the second sensing element of the boiler’s heat exchanger outlet sensor
(EAT %XCHANGER Temperature of the first sensing element of the boiler’s heat exchanger block outlet sensor
(EAT %XCHANGER Temperature of the second sensing element of the boiler’s heat exchanger block sensor
"OILER )N
Temperature of the boiler’s heat exchanger inlet sensor
3YSTEM 3UPPLY
Temperature of the system water after the boiler loop
3YSTEM 2ETURN
Temperature of the system water returning to the boiler loop
&ROM 3ENSOR
Displays where System Supply/Return values are being read from. Most relevant when using multiple sensors connected to the
same Master Boiler Network. When Shadow boilers are connected, this will specify which boiler it is reading.
&LUE
Temperature of the first sensing element of the boiler’s flue gas sensor
&LUE
Temperature of the second sensing element of the boiler’s flue gas sensor
/UTDOOR
Temperature of the remote outdoor air temperature sensor
)NPUTS
3TATUS
Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfied, post purge, Warm Weather
Shut down, Trouble
)NPUT Call for heat status on Input 1 (Input 1 can be TT1 or 0-10VDC input)
)NPUT Call for heat status on Input 2
)NPUT Call for heat status on Input 3
n6 )NPUT
Voltage input for target adjust or modulation for single boiler
,INKED TO -ASTER
For Multiple Boiler Networks. Shows if current control is connected to Master boiler
$EMAND OF -ASTER
For Multiple Boiler Networks. Shows if the Master boiler is calling this boiler heat demand
-ANUAL ,IMIT
External manual limit on low voltage terminal strip
!UTO ,IMIT
External auto limit on low voltage terminal strip
,OW 7TR #UTOFF
Low water cutoff device (inside boiler jacket)
!IR 0 3WITCH
Limit device (inside boiler jacket) that will shut off the boiler if flue pressure becomes too high
'AS 0 3WITCH
Limit device that will shut off the boiler if gas pressure gets too high or low
#LOSURE 3WITCH
P7 jumper circuit closed or open (flow switch, CAD, etc.)
"LOWER 3PEED
Feedback from blower sensor
&LAME 3IGNAL
Number indicating the presence and quality of the flame used to shut down or boost the boiler
/UTPUTS
3TATUS
Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfied, post purge, Warm Weather
Shut down, Trouble
'AS 6ALVE
Control’s gas valve circuit status
#IRCULATOR Control’s circulator 1 relay status
#IRCULATOR Control’s circulator 2 relay status
#IRCULATOR Control’s circulator 3 relay status
"OILER #IRC Boiler’s circulator
"LOWER 3IGNAL
Control’s signal controlling the blower speed
!DDITIONAL (EAT $EMAND
Additional heat demand contact status
!LARM
Alarm contact status
n6 /UTPUT
Voltage being output, by P16, pins 1 & 2
Part number 550-100-168/0516
79
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIAGNOSTICS menu (continued)
&IGURE $)!'./34)#3 menu details (continued) (see Figure 58, page 70 for access information)
-ENU)TEM
#OMMENT
2UN 4IMES
"URNER 4IME
2OTATE 4IME
)NPUT 4IME
)NPUT 4IME
)NPUT 4IME
.ETWORK 4IME
)GNITION #OUNT
-ASTER 3HADOW
#OMM
"OILER )$
,INKED TO -ASTER
"OILERS ON .ETWORK
2EQUESTED TO 2UN
4YPE
2EQUESTED -OD 2ATE
-AX "OILER 4EMP
"OILER /N $IFF
"OILER /FF $IFF
.ETWORK "OILERS
&
/& ",2
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
Records time this boiler was running on a network call for heat generated by the Master boiler
Displays total number of successful ignitions
Displays boiler control type and ID number
Shows if control is currently linked to a Master control
Shows number of boilers currently on network
Shows if this control is being requested to satisfy a network call
Shows whether the control is Network-P1, Network-P2, or NONE
Rate coming from the Master
Displays maximum allowable boiler temperature
Temperature differential from master boiler for network priorities
Temperature differential from master boiler for network priorities
&OR MULTIPLE BOILERS ONLY n 3EE 3LIM&IT !DVANCED MANUAL
Shows current rate of boiler
Shows Boiler Out temperature of boiler
Shows priority being satisfied, updated based on active demand
Shows system type of call for heat, updated based on active demand
Shows the sequence position of that boiler in all the boilers available
Shows boiler number this data belongs to
.ETWORK )NPUTS
"OILER NUMBER
)NPUTS
Displays boiler number
Displays input’s configuration and whether it is active. If input is active, it will be displayed in BOLD print
3OFTWARE 6ERSIONS
Display
Main Micro
Second Micro
4/ 2%3%4
!,, ()34/29
#/5.4%23 4/
:%2/
Software version of the microprocessor on the display circuit board
Software version of the main microprocessor on the control circuit board
Software version of the second microprocessor on the control circuit board
To reset all history counters to zero: Enter the DIAGNOSTICS menu. Then press and hold the left and right arrows
located below the control display. Hold for 5 seconds. This will cause ALL history to be deleted. To maintain
history, reset counters individually.
0!34 %22/23
#ONTROL &AULT
)GNITION 2ETRIES
-ANUAL 2ESET #NT
!UTO 2ESET #NT
,OCKOUT (ISTORY &AULT .AME
&AULT 4YPE
80
Displays number of control faults
Displays cumulative ignition attempts. It is recommended that his be reset during yearly maintenance by holding down the Left and
Right arrows or by selecting this line and pressing the Enter button
Displays number of manual reset lockouts since last cleared
Displays number of auto reset lockouts since last cleared
Choose this to view the most recent error recorded
Displays the name of the fault that occurred
Displays the type of fault that occurred
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
DIAGNOSTICS menu (continued)
&IGURE $)!'./34)#3 menu details (continued) (see Figure 58, page 70 for access information)
-ENU)TEM
4IME
$ATE
3TATUS
4EMPERATURES
)NPUTS
/UTPUTS
,OCKOUT (ISTORY &AULT .AME
&AULT 4YPE
4IME
$ATE
3TATUS
4EMPERATURES
)NPUTS
/UTPUTS
,OCKOUT (ISTORY &AULT .AME
&AULT 4YPE
4IME
$ATE
3TATUS
4EMPERATURES
)NPUTS
/UTPUTS
-ANUAL 4EST -ODE
Status
#OMMENT
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
Choose this to view the second most recent error recorded
Displays the name of the fault that occurred
Displays the type of fault that occurred
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
Choose this to view the third most recent error recorded
Displays the name of the fault that occurred
Displays the type of fault that occurred
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
Heat Exchanger
Target
Modulation
Boiler Out
Boiler In
System Supply
System Return
Flue
Outdoor
Blower Signal
Blower Speed
Flame Signal
Force Rate
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 heat exchanger block sensor
Calculated target temperature based on outdoor temp or the max target if no ODR
Displays what sensor the boiler is using to modulate from. If the boiler is being self-limited, this may also display what the cause is
Temperature of the outlet sensor on the boiler heat exchanger
Temperature of the inlet sensor on the boiler heat exchanger
Temperature of the system water after the boiler loop
Temperature of the system water returning to the boiler loop
Temperature of flue gases
Temperature of outdoor air
Control’s signal controlling the blower speed
Blower’s feedback to the control
Number indicating the presence and quality of the flame used to shut down or boost the boiler
Used to manually force a rate during a call for heat. Choose auto for normal operation
-ANUAL 2ESET
Reset selected condition
Part number 550-100-168/0516
81
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
MAINTENANCE, DATE AND TIME menus
&IGURE -!).4%.!.#% $!4% !.$ 4)-% menus — navigation (see Figure 58, page 70 for access information)
-AINTENANCE )NFO
#OMMENT
Name
Phone
Model
CP Number
Installed
Last Date
Next Date
Interval Settings
Reset Reminder
Contractor name to appear in maintenance reminders and during lockouts
Contractor phone number
Displays the boiler model selected in the boiler setup
Enter the CP# of the boiler
Enter the date the boiler was installed
Date automatically entered when Reset Reminder is chosen by contractor
Date automatically calculated when Reset Reminder is selected by contractor
Contractor selects maintenance reminder frequency based on service history
Contractor selects this to update Last maintenance Date and Next Date. Homeowner uses this to ignore the reminder and
update only the Next Date.
3ET 4IME AND $ATE
Year
Month
Day
Hour
Minute
Set year (homeowner or contractor)
Set month (homeowner or contractor)
Set day (homeowner or contractor)
Set hour (homeowner or contractor)
Set minute (homeowner or contractor)
MAINTENANCE INFO
1. Use this section to enter contractor’s information, CP number, install date and to enter an automatic notice for maintenance (default is 12 months). Because this shows on the display, it is an automatic means of notifying the homeowner of need for scheduled
maintenance by the technician. Select RESET REMINDER to reset for the next maintenance date.
SET TIME AND DATE
1. Enter current date and time. This allows correct maintenance reminder timing and provides date and time stamp for lockout
histories on ERROR screen in Diagnostic Menu.
82
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Startup — fill the system
Clean system to remove sediment
Antifreeze
1. You must thoroughly flush the system (without boiler
connected) to remove sediment. The high-efficiency heat
exchanger can be damaged by buildup or corrosion due to
sediment.
1. Use only antifreeze listed by Weil-McLain as suitable for
use with SlimFit Gas Boilers. A list of approved antifreeze
products is available at www.Weil-McLain.com.
2. See Replacement parts at the end of this manual for WeilMcLain part numbers to obtain antifreeze through a WeilMcLain distributor.
2. If necessary, use an approved chemical cleaning agent, following the manufacturer’s guidelines for procedures. A list of
approved cleaning products is available at www.Weil-McLain.
com. See Replacement parts at the end of this manual for
Weil-McLain part numbers to obtain cleaning agents through
a Weil-McLain distributor.
3. For zoned systems, flush each zone separately through a purge
valve. (If purge valves and isolation valves are not already
installed, install them to properly clean the system.)
4. Flush system until water runs clean and you are sure piping
is free of sediment.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Damage to elastomer seals and gaskets in system could occur,
resulting in substantial property damage.
Before filling the boiler and system with water,
verify the following. $/ ./4 lLL WITH SOFTENED
WATER Boiler corrosion can occur.
Failure to comply could result in boiler failure
or unreliable operation.
Water chemistry
Water pH between 7.0 and 8.5
1. Maintain boiler water pH between 7.0 and 8.5. Check with
litmus paper or have chemically analyzed by water treatment
company.
2. If pH differs from above, consult local water treatment company for treatment needed.
3. Softened water maybe used to fill boiler providing Sentinel
X100 is added to the system at the proper dosage and properly
maintained. Without Sentinel X100, softened water must not
be used or boiler corrosion may occur.
Hardness must be less than 7 grains
1. Consult local water treatment companies for unusually hard
water areas (above 7 grains hardness).
Chlorine concentration must be
LESS THAN 200 ppm
1. Filling with chlorinated fresh water should be acceptable since
drinking water chlorine levels are typically less than 5 ppm.
2. Do not use the boiler to directly heat swimming pool or
spa water.
3. Do not fill boiler or operate with water containing chlorine
in excess of 200 ppm.
Part number 550-100-168/0516
Use the correct amount of antifreeze
1. Determine the freezing temperature needed (to protect
against lowest likely temperature the system water will
encounter).
2. Find the antifreeze concentration by volume needed for this
temperature from the antifreeze manufacturer’s data on the
antifreeze container. $/ ./4 exceed 50% by volume concentration of antifreeze.
3. Add up the volume (gallons) of all system piping and components, including the expansion tank and boiler.
a. Boiler water content is listed on page 121.
b. Remember to include expansion tank water content.
4. Multiply this volume by the (percent) antifreeze needed to
find the number of gallons of antifreeze to add.
Fill and test water system
1. Fill system only after ensuring the water meets the requirements of this manual.
2. Close manual and automatic air vents and boiler drain valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. Pressure will rise when boiler is turned on and system
water temperature increases. Operating pressure must
never exceed 80 psig.
4. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
Eliminate all system leaks. Continual fresh make-up
water will reduce boiler life. Minerals can build up
in sections, reducing heat transfer, overheating heat
exchanger, and causing heat exchanger failure.
Purge air from water system
1. Connect a hose to the purge valve (see purge/drain valves,
item 11, in piping diagrams beginning on page 14. Route hose
to an area where water can drain and be seen.
2. Close the boiler or system isolation valve between the purge
valve and fill connection to the system.
3. Close zone isolation valves.
4. Open quick-fill valve on cold water make-up line.
5. Open purge valve.
6. One zone at a time, open the isolation valves. Allow water
to run through the zone, pushing out the air. Run until no
noticeable air flow is present. Close the zone isolation valves
and proceed with the next zone. Follow this procedure until
all zones are purged.
83
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Startup — fill the system (continued)
Freeze protection (when used)
Follow these guidelines to prevent possibility of severe personal injury, death
or substantial property damage:
8. After the system has operated for a while, eliminate any residual air by
using the manual air vents located throughout the system.
.%6%2 USE AUTOMOTIVE OR STANDARD
GLYCOL ANTIFREEZE, EVEN GLYCOL MADE
FOR HYDRONIC SYSTEMS . Use only
9. If purge valves are not installed in system, open manual air vents in
system one at a time, beginning with lowest floor. Close vent when
water squirts out. Repeat with remaining vents.
freeze-prevention fluids recommended
by Weil-McLain for application in SlimFit Boiler systems.
10. Open automatic air vent (diaphragm-type or bladder-type expansion
tank systems only) one turn.
4HOROUGHLY mUSH ANY SYSTEM THAT
HAS USED GLYCOL before installing the
11. Starting on the lowest floor, open air vents one at a time until water
squirts out.
new SlimFit boiler.
12. Repeat with remaining vents.
2EVIEW THE MATERIAL SAFETY DATA
SHEET -3$3 for the fluid used with
13. Refill to correct pressure.
the boiler owner and leave a copy for
reference. The MSDS contains information on potential hazards and first aid
procedures for exposure or ingestion.
Use inhibitor supplied with boiler
#HECK ANTIFREEZE INHIBITOR LEVEL AT
LEAST ANNUALLY. Glycol concentration
and inhibitor levels may change over
time. Add antifreeze to increase concentration if necessary. Add inhibitor
as needed to bring to acceptable level,
using inhibitor test kit to verify.
When using freeze protection fluid with
automatic fill, INSTALL A WATER METER TO
MONITOR WATER MAKE UP. Freeze protection fluid may leak before the water
begins to leak, causing concentration
to drop, reducing the freeze protection
level.
$/ ./4 EXCEED ANTIFREEZE
BY VOLUME. Antifreeze moves more
sluggishly than water and can interfere
with heat transfer. At antifreeze concentrations higher than 50%, sludge can
develop in the boiler, potentially causing
damage to the heat exchanger.
#LEAN THE SYSTEM BEFORE FILLING.
Always drain and flush the system
thoroughly before filling with antifreeze.
Sludge, iron oxide deposits and other
sediment in the system inhibit flow and
can cause rapid breakdown of inhibitors.
Use only antifreeze recommended by
Weil-McLain.
Weil-McLain provides information for
application of the antifreeze products
listed in this document only for use in
Weil-McLain SlimFit boilers. Do not
apply these products or instructions
for other applications. Local codes may
require a backflow preventer or actual
disconnection from city water supply.
84
7. Close the quick-fill water valve and purge valve and remove the hose.
Open all isolation valves. Watch that system pressure rises to correct
cold-fill pressure.
1. The SlimFit boiler is shipped with Sentinel X100 inhibitor and Sentinel inhibitor test kit. See Repair Parts at the end of this manual for
re-ordering information.
2. After filling the system as directed in these instructions, use a caulking
gun to inject the X100 inhibitor into the system, following the instructions on the tube.
3. Inject all of the inhibitor supplied with the boiler. Allow time for the
water to circulate and mix. Then check the inhibitor level. Add additional inhibitor if necessary.
Check/verify water chemistry
1. The system may have residual substances that could affect water
chemistry.
2. After the system has been filled and leak tested, verify water pH and
chlorine concentrations are acceptable.
3. Verify antifreeze concentration, when used.
4. Follow the instructions on the Sentinel test kit to sample the system
water and verify inhibitor concentration.
Check inhibitor and antifreeze concentrations
annually
1. Test the pH of a sample of system water at least annually. The pH of
the water mixture must be between 7.0 and 8.5. (Or use the Sentinel
inhibitor test kit to check concentration.)
2. If pH is outside this range (or inhibitor test kit indicates low level), the
inhibitor level may not be sufficient to prevent corrosion.
3. Test antifreeze concentration.
Test antifreeze concentration at least annually. If concentration is low, add antifreeze or drain system and refill with
correct mixture. Follow instructions on page 83 to determine
amount of antifreeze needed.
4. Check inhibitor level after adjustments are made.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Startup — final checks
Check for gas leaks
Before starting the boiler, and during initial operation, use a leak detector or smell near the floor and
around the boiler for gas odorant or any unusual
odor. Remove boiler front door and smell interior
of boiler enclosure. Do not proceed with startup if
there is any indication of a gas leak. Repair any leak
at once.
DO NOT adjust or attempt to measure gas valve
outlet pressure. The gas valve is factory-set for the
correct outlet pressure. This setting is suitable for
natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve
outlet pressure could result in damage to the valve,
causing potential severe personal injury, death or
substantial property damage.
Propane boilers only — Your propane supplier
mixes an odorant with the propane to make its
presence detectable. In some instances, the odorant
can fade, and the gas may no longer have an odor.
Before startup (and periodically thereafter), have the
propane supplier verify the correct odorant level in
the gas.
Check thermostat circuit(s)
1. Disconnect the two external wires connected to the boiler thermostat terminals (see Field wiring, beginning on page 50 for terminal
locations).
2. Connect a voltmeter across these two incoming wires. Close each
thermostat, zone valve and relay in the external circuit one at a
time and check the voltmeter reading across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and correct the
external wiring. (This is a common problem when using 3-wire
zone valves.)
5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires.
Allow the boiler to cycle.
Inspect/fill condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC fittings and
condensate trap. (See page 46 for component locations.)
2. Pour water into the top of the boiler’s 1” PVC condensate tee and
check for any leaks in the condensate drain line or fittings. Repair
any leaks.
Fill condensate trap with water
1. Remove boiler front door.
2. Remove the flue inspection plug (item 45, page 3).
3. Pour fresh water into the flue inspection opening until the condensate trap is full of water (water begins to flow out through
condensate drain tee).
Part number 550-100-168/0516
4. Replace the flue inspection plug.
The condensate trap must be filled with water
during all times of boiler operation to avoid
flue gas emission from the condensate drain
line. Failure to fill the trap could result in
severe personal injury or death.
Final checks before starting boiler
❏ Read the instructions to adjust and set up the Control
module.
❏ Verify that the boiler model is set correctly in the Control, and that it displays correctly.
❏ Verify that the boiler and system are full of water and
all system components are correctly set for operation.
❏ Fill condensate trap with water (see above for procedure).
❏ Verify electrical connections are correct and securely
attached.
❏ Inspect vent piping and air piping for signs of deterioration from corrosion, physical damage or sagging.
Verify air piping and vent piping are intact and correctly
installed per this manual.
To start the boiler
1. Turn OFF the boiler ON/OFF switch.
2. Read and follow the Operating Instructions, Figure 75,
page 88.
3. The Control display will show installed sensors when
first powered. Make sure the right sensors are detected. If
not, determine the cause and correct before proceeding.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service
switch off?
2. Is external limit control (if used) open? Is boiler water
temperature above 200 °F?
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler?
5. Is incoming gas pressure greater or less than required
on page 49 (natural gas) or (propane)?
6. Are parameters set correctly as per this manual?
7. Is the warm weather shutdown activated?
8. If none of the above corrects the problem, refer to
Troubleshooting, beginning on page 96.
❏ Check system and boiler
❏
Check water piping
1. Check system piping for leaks. If found, shut down boiler
and repair immediately. (See WARNING on page 83
regarding failure to repair leaks.)
2. Vent any remaining air from system using manual vents.
Air in the system will interfere with circulation and cause
heat distribution problems and noise.
85
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Startup — final checks (continued)
❏
Check vent piping and air piping
If combustion at either high or low fire is
outside the range given in Figure 73, follow the procedure given for adjusting the
throttle screw on the gas valve. If throttle
screw adjustment does not correct the
problem, then shut down the boiler and
contact your local Weil-McLain representative. Throttle screw adjustment must
be done only by a qualified technician,
using calibrated test instruments. Failure
to comply could result in severe personal
injury, death or substantial property
damage.
1. Check for gas-tight seal at every connection and seam of air
piping and vent piping.
Venting system must be sealed gas-tight to prevent flue
gas spillage and carbon monoxide emissions which will
result in severe personal injury or death.
❏
Check gas piping
1. Check around the boiler for gas odor following the procedure
of page 48 of this manual.
If you discover evidence of any gas leak, shut down
the boiler at once. Find the leak source with bubble
test and repair immediately. Do not start boiler again
until corrected. Failure to comply could result in severe
personal injury, death or substantial property damage.
❏
DO NOT adjust or attempt to measure gas valve
outlet pressure. The gas valve is factory-set for the
correct outlet pressure. This setting is suitable for
natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve
outlet pressure could result in damage to the valve,
causing potential severe personal injury, death or
substantial property damage.
SlimFit boilers are shipped ready to fire natural gas
ONLY. You must install the propane orifice if the
boiler will be connected to propane. See page 9.
Failure to comply could result in severe personal
injury, death or substantial property damage.
(IGH lRE
"OILER
&UEL
3&
550
3&
750
,OW lRE
#/2
#/
PPM
#/2
#/
PPM
.'
,0
.'
,0
These values are for altitudes up to 5,500 feet. For higher
altitudes, CO2 may be slightly lower and CO slightly higher.
1. Measure natural gas input:
a. Operate boiler 10 minutes.
b. Turn off other appliances.
c. At natural gas meter, measure time (in seconds) required to use one cubic foot of gas.
d. Calculate gas input:
Check flame & combustion with instruments
1. Initiate a call for heat on one of the heat demand inputs.
2. Access the Control installer menus by pressing and holding the
UP and DOWN arrow keys for five seconds.
3. Use the Control display to navigate DIAGNOSTICS to Manual
test mode (see page 95 for proper instructions on forcing rates
during Manual Test Mode) and force the firing rate to High
(high fire).
4. Look at the flame through the flame inspection window. The
high fire flame should be blue and should be stable. The burner
surface should be covered with orange dots.
5. Remove the flue temperature sensor from the flue pipe and
insert a combustion test probe., using a calibrated combustion
test instrument.
6. Test for CO2 (or O2) and for CO. The CO2 values must be within
1% of the values listed in Figure 73. If results are acceptable,
proceed to step 7. IF NOT, follow the instructions under “Gas
valve adjustment procedure” on page 87 to set the CO2 values.
See WARNING in next column.
86
be within 1.0% of these values)
Propane boilers — verify conversion
1. Verify propane orifice has been installed per Propane Conversion instructions.
❏
&IGURE Acceptable CO2 and CO values (CO2 must
3600 x 1000
= Btuh
number of seconds from step c
2.
3.
4.
5.
6.
e. Btuh calculated should approximate input rating on
boiler rating label.
Use the Control display to navigate to Manual test mode
(see Figure 68, page 78) and force the firing rate to Low
(low fire).
Look at the flame through the flame inspection window.
The low fire flame should be stable and evenly distributed
over burner surface with a uniform orange color.
Repeat the combustion test of steps 5 and 6 above.
Use the Control display to navigate to Manual test mode
(see Figure 68, page 78) and force the firing rate to AUTO
(normal operation).
Re-install the flue gas temperature sensor.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Startup — final checks (continued)
You must re-install the flue gas temperature sensor
to prevent flue gas spillage into the boiler enclosure.
Failure to comply could result in severe personal
injury, death or substantial property damage.
&IGURE Throttle screw location (ONLY for use by
a qualified technician, using calibrated
combustion test instruments)
Gas valve adjustment procedure
DO NOT attempt to adjust the gas valve settings unless you are a qualified technician, and with the use of
calibrated combustion test instruments. Adjust the
valve settings only as needed to meet the combustion
values given in Figure 73, page 86.
1. This procedure is only necessary when combustion tests
indicate the need, as explained under “❏ Check flame &
combustion with instruments, page 86.”
2. Boiler behavior that might indicate a need to check combustion values at high fire (as per page 86) to verify boiler is in
adjustment include: difficulty igniting, poor flame stability at
low fire, combustion noise or high carbon monoxide values.
3. Combustion readings must be taken at both high fire and
low fire.
Adjust valve at high fire
1. Use the Control display to navigate to Manual test mode (see
Figure 68, page 78) and force the firing rate to High (high fire).
(See page 95 for proper instructions on forcing rates during
Manual Test Mode). After the boiler has had time to stabilize
and high-fire RPM value (see Figure 78, page 95) is reached,
take a CO2 reading.
a. See Figure 74 to adjust if necessary.
b. Remove the blue cover on the throttle screw opening with
a straight-bit screwdriver.
Make only small (1/8-turn) throttle screw adjustments. Adjustment can be sensitive, especially on
propane. Navigate to DIAGNOSTICS — Manual
test mode (see page 95 for proper instructions on
testing).
If the CO2 is HIGH, turn the throttle screw CLOCKWISE to
lower the input. Allow the boiler to stabilize and
take another reading. Continue until the desired
CO2 value is achieved.
c. If the CO2 is LOW, turn the throttle screw COUNTERCLOCKWISE to increase the input. Allow the boiler to
stabilize and take another reading. Continue until the
desired CO2 value is achieved.
d. Re-install the blue cover on the gas valve.
Adjust valve at low fire
1. Lock the boiler into low fire using the Control module screen.
Verify that the blower rpm value is correct for low fire (see
Figure 78, page 95).
2. Check the combustion readings.
3. If results are acceptable at low fire, verify high fire readings
again. Restore firing rate to AUTO.
4. If combustion results are not acceptable, remove the cover
screw over the offset adjustment (see Figure 74). Navigate to
Part number 550-100-168/0516
DIAGNOSTICS — Manual test mode (see page 95 for proper
instructions on testing).
5. Use a T40 Torx driver to adjust the setting. Rotate clockwise
to increase CO2, rotate counterclockwise to decrease CO2.
Re-install the cover screw when completed.
6. Consult your local Weil-McLain representative if acceptable
results cannot be obtained for both high and low fire.
❏ Adjust and test boiler controls
1. Follow instructions in this manual to set and verify operation of the boiler controls.
❏
Check ignition system safety shutoff device
1. After the boiler has been installed, turn off the boiler.
2. Shut off the manual gas valve located on the gas line to stop
flow of fuel to the boiler.
3. Turn on the boiler. It will start the ignition sequence, but will
not light. After some time, the boiler will lockout, the display
screen will turn red, and the Control will flash “Ignition
Fault”. It means that the boiler tried to ignite without success
for five (5) times and went into Lockout mode. This means
that the ignition system safety device worked properly.
4. Clear the Lockout condition by selecting “Manual Reset” in
the Diagnostic Menu.
5. Open the manual gas valve located on the gas line to resume
fuel supply to the boiler.
87
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Operating Instructions
&IGURE Operating instructions (WARNING — Verify that the Control is set for the correct boiler model before proceeding.)
88
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Check-out/startup verification
Gas valve leakage testing
Fill out start-up data on the Installation
and Service Certificate, page 123.
❏ Verified that the Control is set for the correct boiler model?
1.
❏ Boiler and heat distribution units filled with water?
2.
❏ Water chemistry verified per page 83?
❏ Automatic air vents, if used, open one full turn?
3.
❏ Air purged from system?
❏ Air purged from gas piping? Piping checked for leaks?
❏ Primed condensate trap?
❏ Propane conversion kit installed for propane firing and
propane conversion label affixed to jacket?
SlimFit boilers are shipped ready to fire natural
gas ONLY. You must install the propane conversion kit if the boiler will be connected to propane. See page 8. Failure to comply could result
in severe personal injury, death or substantial
property damage.
❏ Thermostat circuit wiring checked to ensure there are no
stray voltages?
❏ Followed Operating Instructions, Figure 75, page 88
4.
5.
6.
7.
8.
DO NOT connect a manometer to the manual gas valve or
the automatic gas valve. The high vacuum from the blower
could pull fluid into the gas line, possibly damaging the
gas valves.
Refer to the gas valve manufacturer’s instructions for the procedure
to test the valve.
To operate the two valve solenoids independently, navigate to the Valve
Test Screen on the Control (see Figure 67, page 77 for access sequence).
When in the Gas Valve Test Screen, you will see two options:
a. Open Gas Valve 1
b. Open Gas Valve 2
To open only gas valve 1, highlight it and press enter/save.
While still in the Gas Valve test screen, give the boiler a call for heat.
The boiler will go through it’s normal Ignition sequence, but will
only open Gas Valve 1.
After gas valve 1 has opened, end the call for heat.
This procedure can be repeated by selecting and entering Open Gas
Valve 2.
After the testing is complete and the call for heat has been removed,
use the back button to exit the Gas Valve Test Screen. This will then
reset the control to open both Gas Valves for any call for heat.
&IGURE Gas valve test pressure tappings
❏ Burner flame and combustion verified per page 86?
❏ Verified control operation for space heating and DHW (if
used) per this manual?
❏ Tested additional field-installed controls — If boiler has
additional limits, have they been tested for operation as
outlined by manufacturer? (Boiler should be operating and
should go off when controls are tested. Verify controls cause
automatic reset lockout or manual reset lockout as desired.)
Use manual gas valve
side tapping for pressure
connection after gas valve 2.
❏ Set additional field-installed limit control(s) to system
temperature requirements? Adjusted balancing valves and
controls to provide design temperature to system?
❏ For multiple zones, adjusted for correct flow in each zone?
❏ Verified thermostat heat anticipator (if available) set properly (see page 63 for requirements)?
❏ Cycled boiler with thermostat (and with DHW aquastat,
if installed) — Raised to highest setting and verified boiler
goes through normal startup cycle? Lowered to lowest setting and verified boiler goes off?
Use tapping P on gas valve body for pressure connection
after gas valve 1 or between the gas valve seats.
❏ Measured natural gas input? (page 86)
❏ Checked incoming gas pressure as specified on page 49
(natural gas) or (propane).
❏ Observed several operating cycles for proper operation.
❏ Set room thermostat to desired room temperature (and
DHW aquastat, if installed, to desired DHW storage
temperature)?
❏ Reviewed all instructions shipped with this boiler with
owner or maintenance person?
❏ Fill in )NSTALLATION CERTIlCATE on page 123.
❏ Fill out the warranty registration card and send to
Weil-McLain.
❏ Return instructions to envelope and give to owner or place
inside boiler housing.
Part number 550-100-168/0516
Gas pressure switch settings
1. After testing the gas pressure switches, restore the settings to the
following:
a. High gas pressure switch — 14” w.c.
b. Low gas pressure switch — 2” w.c.
Install a 100% lockup gas pressure regulator in the gas
supply line if inlet pressure can exceed 14” w.c. at any
time. Adjust the lockup regulator for 7 to 10” w.c. inlet
pressure. This setting provides a cushion below the setting of the high gas pressure switch. Failure to comply
could result in shutdown by the high gas pressure switch,
resulting in possible serious property damage due to
freeze-up.
89
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Annual startup and general maintenance
&IGURE Service and maintenance schedules
Service technician
Owner maintenance
(see following pages for instructions)
(see SlimFit User’s Information Manual for instructions)
General:
Reported problems.
s Check boiler area.
Inspect interior; clean and vacuum if
necessary; WARNING — no solvents.
s Check air openings.
!..5!, 34!24 50 3EE &IRST YEAR SPECIAL INSPECTION
Clean base collector and condensate trap
and fill with fresh water.
$AILY
Check for leaks (water, gas, flue,
condensate).
s Check pressure/temperature
gauge.
s Verify boiler front door is securely
in place.
Check system water chemistry, inhibitor
level and antifreeze concentration, if used.
Verify flue and air lines in good condition
and sealed tight.
Check system water pressure/system
piping/expansion tank.
s Check vent piping.
Check control settings.
s Check air piping.
Ignition electrode (clean with steel wool and
reposition).
-ONTHLY
s Check relief valve.
Ignition and ground wiring.
s Check condensate drain system.
Wiring and connections.
s Check automatic air vents (if
used).
Perform start-up checkout and performance
verification beginning with Startup — fill the
system, page 83.
Flame inspection (stable, uniform).
Flame signal (see Figure 81, page 94).
0ERIODICALLY
s Test low water cutoff by pressing
test button.
Clean heat exchanger if flue temp is more
than 54°F above return water temp.
Inspect jacket front door gaskets; replace if
necessary.
%VERY
MONTHS
s Check boiler piping (gas and
water).
s Operate relief valve.
Additional if combustion or
performance indicate need:
Clean heat exchanger.
Remove and clean burner using
compressed air only.
Vacuum the blower.
%ND
OF SEASON
s Shut boiler down (unless boiler
used for domestic water).
Review:
Review with owner.
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.
90
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Annual startup
HANDLING CERAMIC FIBER
MATERIALS
REMOVAL OF SIGHT GLASS GASKET
The sight glass gasket in this product
contains ceramic fiber materials that have
been identified as carcinogenic, or possibly carcinogenic, to humans. Ceramic
fibers can be converted to cristobalite in
very high temperature applications. The
International Agency for Research on
Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or
cristobalite from occupational sources is
carcinogenic to humans (Group 1).”:
❏ Avoid breathing dust and contact with skin and eyes.
s
s
Use NIOSH certified dust respirator (N95).
This type of respirator is based on the OSHA
requirements for cristobalite at the time this
document was written. Other types of respirators may be needed depending on the job site
conditions. Current NIOSH recommendations
can be found on the NIOSH web site at http://
www.cdc.gov/niosh/homepage.html. NIOSH
approved respirators, manufacturers, and
phone numbers are also listed on this web site.
Wear long-sleeved, loose fitting clothing,
gloves, and eye protection.
❏ Apply enough water to the sight glass gasket to
prevent airborne dust.
❏ Remove sight glass gasket from the boiler and place
it in a plastic bag for disposal.
❏ Wash potentially contaminated clothes separately
from other clothing. Rinse clothes washer thoroughly.
FIRST-YEAR SPECIAL INSPECTION
1. .O LATER THAN MONTHS after the boiler is installed, perform a first-year inspection of the boiler.
This must include the following IN ADDITION TO
ROUTINE ANNUAL START UP PROCEDURES.
a. Remove the heat exchanger cover plate. Inspect
the heat exchanger and clean if necessary. See
instructions for removing and replacing the
heat exchanger cover plate, and for cleaning
the heat exchanger, in the Maintenance section
of this manual.
b. Make sure the burner is clean.
c. Make sure the burner gasket is in good condition. Replace if necessary.
d. Disconnect condensate trap and drain lines.
Inspect, then flush thoroughly.
2. Determine follow-up maintenance and service
needs based on the condition of the heat exchanger
and condensate lines.
a. If the heat exchanger shows substantial fouling,
or if condensate lines show accumulation of
sediment, schedule a follow-up service call to
perform the first-year inspection again, sooner
than the normal twelve months between.
b. Heavy fouling of the exchanger or condensate
lines indicates possible combustion air contamination. Inspect the air intake area carefully, and
remove possible contaminants. See “ Corrosive
contaminants and sources,” Figure 12, page 22,
for products to avoid.
NIOSH stated First Aid
❏ Eye: Irrigate immediately
❏ Breathing: Fresh air.
Part number 550-100-168/0516
You must eliminate causes of corrosion
and contamination to ensure reliable
operation of the boiler and system.
91
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Annual startup (continued)
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 77, page 90 and
explained on the following pages must be
performed to assure maximum boiler efficiency and reliability. Failure to service and
maintain the boiler and system could result
in equipment failure.
Electrical shock hazard — Turn off power
to the boiler before any service operation on
the boiler except as noted otherwise in this
instruction manual. Failure to turn off electrical power could result in electrical shock,
causing severe personal injury or death.
Address reported problems
1. Inspect any problems reported by owner and correct before
proceeding.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids.
2. Verify that air intake area is free of any of the contaminants
listed on page 22 of this manual. If any of these are present
in the boiler intake air vicinity, they must be removed. If they
cannot be removed, reinstall the air and vent lines per this
manual and the SlimFit Boiler Vent Supplement.
Inspect boiler interior & door gaskets
1. Remove front door and inspect interior of boiler.
2. Visually inspect the door gaskets. Make sure all are in good
condition. Obtain replacements if any gasket is damaged.
Door gaskets must be intact, and must provide a
reliable seal. Replace any damaged gasket.
3. Remove the venturi air inlet silencer and clean if necessary.
Replace silencer.
4. Vacuum any sediment from the inside of the boiler and
components. Remove any obstructions.
Do not use solvents to clean any of the boiler
components. The components could be damaged,
resulting in unreliable or unsafe operation.
Clean condensate trap
1. Remove flue inspection plug (item 45, page 3).
2. Inspect base collector with flash light. Flush out with water
as needed.
3. Loosen condensate trap line hose clamps and remove trap
line.
4. Empty water from trap line and inspect. Flush out if needed
with fresh water.
92
5. Check condensate fittings and condensate line to drain. Flush
if necessary to clean.
6. Reinstall condensate trap line and tighten hose clamps.
7. Fill trap with fresh water by pouring into flue inspection
plug opening.
8. Replace flue inspection plug.
Check all piping for leaks
Eliminate all system or boiler leaks. Continual fresh
make-up water will reduce boiler life. Minerals
can build up in sections, reducing heat transfer,
overheating heat exchanger, and causing heat
exchanger failure. Leaking water may also cause
severe property damage.
1. Inspect all water and gas piping and verify to be leak free.
2. Look for signs of leaking lines and correct any problems
found.
3. Check gas line using procedure on page 48.
Check air openings
1. Verify that combustion and ventilation air openings to the
boiler room and/or building are open and unobstructed.
Check operation and wiring of automatic combustion air
dampers, if used.
2. Verify that boiler vent discharge and air intake are clean and
free of obstructions.
Flue vent system and combustion air
piping
1. Visually inspect entire flue gas venting system (and air piping, if installed) for blockage, deterioration or leakage. Repair
any joints that show signs of leakage in accordance with vent
manufacturer’s instructions. When air is ducted to boiler,
verify that air inlet pipe is connected and properly sealed.
Failure to inspect for the above conditions and have
them repaired can result in severe personal injury
or death.
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is correct
(usually around 12 psig).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure doesn’t rise too high. Excessive
pressure rise indicates expansion tank sizing or performance
problem.
4. Inspect automatic air vents and air separators. Remove air
vent caps and briefly press push valve to flush vent. Reinstall
caps. Make sure vents do not leak. Replace any leaking vents.
5. Check system water chemistry (inhibitor concentration, pH
and hardness). See page 83.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Annual startup (continued)
Check expansion tank
Check ignition wiring
1. Expansion tanks provide space for water to move in and
out as the heating system water expands due to temperature
increase or contracts as the water cools. Tanks may be open,
closed or diaphragm or bladder type. See pages 14-19, of this
manual for suggested best location of expansion tanks and
air eliminators.
s Open-type — located above highest radiator or baseboard
unit, usually in the attic or closet. Has a gauge glass and
overflow pipe to a drain.
s Closed-type — welded gas tight and located above boiler.
Tank is partially filled with water, leaving an air cushion
for expansion.
s Make sure this type of tank is fitted with a tank fitting,
such as the B & G Tank-Trol or Taco Taco-Trol. This
fitting reduces gravity circulation of air-saturated
tank water back to the system and prevents the air
from bubbling up through the water as it returns
from the system.
s Do not use automatic air vents in systems with closedtype tanks. The air will escape from the system instead
of returning to the tank. Eventually, the tank will
waterlog and no longer control pressurization. The
boiler relief valve will weep frequently.
s Diaphragm- or bladder-type — welded gas tight with
a rubber membrane to separate the tank pressurizing air
and the water. May be located at any point in the system,
but most often found near the boiler.
s Systems with this type of expansion tank require at
least one automatic air vent, preferably located on
top of an air eliminator, as shown in examples in
this manual.
2. If relief valve has tended to weep frequently, the expansion
tank may be waterlogged or undersized.
s Closed-type tank — tank is most likely waterlogged.
Install a tank fitting if not already installed. Then check
fill level per fitting manufacturer’s instructions. If fill
level is correct, check tank size against manufacturer’s
instructions. Replace with a larger tank if necessary.
s Diaphragm- or bladder-type — first, check tank size to
be sure it is large enough for the system. If size is too small,
add additional tank (or tanks) as necessary to provide
sufficient expansion. If tank size is large enough, remove
tank from system and check charge pressure (usually 12
psig for residential applications). If tank won’t hold pressure, membrane has been damaged. Replace tank.
1. Check ignition cable electrical resistance. A good cable will
have resistance between 900 and 1000 ohms. Replace if not
acceptable.
2. Inspect boiler ground wire from ignition electrode to ground
terminal strip.
3. Verify all wiring is in good condition and securely attached.
4. Check ground continuity of wiring using continuity meter.
5. Replace ground wires if results are not satisfactory.
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good condition and securely attached.
Check control settings
1. Use the Control display to navigate through all settings. Adjust
settings if necessary.
2. Check settings of external limit controls (if any) and adjust
if necessary.
Perform startup and checks
1. Start boiler and perform checks and tests specified in this
manual.
2. Verify cold fill pressure is correct and that operating pressure
does not go too high.
3. Complete the check-out procedure on page 89.
Inspect ignition electrode
1. Remove the ignition electrode from the boiler heat exchanger.
2. Remove any white oxides accumulated on the ignition electrode using steel wool. If the ignition electrode cannot be
cleaned satisfactorily, replace ignitor with a new one.
3. Reinstall ignition electrode, making sure gasket is in good
condition and correctly positioned.
4. Replace gasket if necessary.
5. Make sure the ignition electrode ground wire is under the
top screw that secures the ignitor to the casting.
Part number 550-100-168/0516
93
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Annual startup (continued)
Check burner flame (See Figure 79)
1.
2.
3.
4.
5.
The boiler contains ceramic fiber materials. Use care
when handling these materials per instructions on
page 91 of this manual. Failure to comply could
result in severe personal injury.
Inspect flame through the observation window using the
procedure on page 86.
a. The high fire flame should be blue and should be stable.
The burner surface should be covered with orange dots.
b. The low fire flame should be stable and evenly distributed
over burner surface with a uniform orange color.
If the flame is unsatisfactory at either high fire or low fire,
perform the testing specified on page 86. If the problem remains, turn off the boiler and allow the boiler to cool down.
To access the burner, first turn off all power to the boiler:
a. Disconnect the two wire harnesses connected to the
blower.
b. Use a 13-mm socket wrench to remove the three nuts that
secure the mixing tube to the right-end heat exchanger
section (Figure 79).
c. The mixing tube, blower, venturi and gas train can be
pulled to the right to clear the mounting stud, then
pulled forward and placed on a support while working.
(If necessary, disconnect the ignitor ground wire and the
wire harnesses to the gas valve and gas pressure switches.)
Remove the burner gasket and burner (see Figure 80).
Clean the burner ports both inside and outside surfaces, using a vacuum cleaner or compressed air. If necessary, use a
soft-bristled brush to loosen particles.
Do not used compressed air unless doing so outside
and wearing eye protection.
6. To replace the burner:
a. Insert the burner first. When inserting, place your hand
inside the burner throat and tilt the back end of the burner
up until the burner flange meets the heat exchanger. This is
necessary to prevent the burner from rubbing on the heat
exchanger burner support stubs on the left end section.
b. Align the burner flange notch with the notch in the casting
above the burner opening.
c. Inspect the burner gasket. It must be in good condition.
If not, replace with a new gasket (see Replacement parts
at the end of this manual).
d. Place the gasket over the three studs.
The burner-opening studs are unevenly spaced to
ensure the gasket and the mixing tube are properly
positioned.
7. Position the mixing tube over the studs. Replace the three nuts.
Tighten securely (to 12 N-m/106 in-lbs/8.8 ft-lbs).
8. Reconnect any wiring that was disconnected.
9. 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 77). The flame signal value must be at least
20 above the Shutdown values given in Figure 81.
2. If the flame signal drops to less than 20 above the Shutdown
values, the Control will attempt to correct by increasing the
boiler firing rate to increase flame signal.
94
&IGURE Burner access
Observation
window
Nuts
Mixing tube
NOTE: Ignitor ground wire must be attached
to the top ignitor mounting screw.
&IGURE Burner removal and replacement
IMPORTANT — Align the
burner flange notch with the
notch in the casting.
Burner
Gasket
Mixing tube
&IGURE Flame signal shutdown values
-ODEL
3LIM&IT n
3HUTDOWN
mAME SIGNAL
2ESTORE
mAME SIGNAL
550
110
130
750
110
130
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.
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.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
Annual startup (continued)
— Boiler Manual
When forcing a rate on a Network Priority
call, only boilers running Local Priority
calls will remain on. All other boilers on
the network will not fire until the Manual
Test has ended. Ensure critical applications
remain heated. Long periods of low heating
can cause property damage.
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 54 °F higher than
the boiler return temperature.
3. If the flue temperature is higher than this, shut down the boiler, al- 4. The selected boiler will run at the forced rate until it is
either returned to AUTO, the user selects “End Manual
low to cool, and follow the procedure starting on page 105 to clean
Test” on the Master’s Manual Test Mode screen, or after
the heat exchanger.
30 minutes of inactivity on the Master control.
Check blower speeds
5. To test the next boiler, return to the master and select
the next desired boiler to test.
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
Check boiler relief valve
automatically adjusts low fire and ignition rates to compensate for
high altitude conditions.
1. Inspect the relief valve and lift the lever to verify flow as
2. For installations below 5,500 feet, DO NOT enable high altitude.
in the following warnings, excerpted from a relief valve
manufacturer’s warning label. Before operating any relief
3. Use the Control display to navigate to Manual test mode (see
valve, ensure that it is piped with its discharge in a safe
Figure 68, page 78).
area to avoid severe scald potential. Read “Install water
4. Set the firing rate to Low (low fire).
piping” starting on page 12, before proceeding further.
5. Write down the blower RPM value shown and compare to the value
in the table below. Low fire rate (and corresponding blower speed)
is adjusted in the boiler setup menu.
Safety relief valves should be reinspected AT LEAST ONCE
6. Set the firing rate to MEDIUM (ignition rate).
EVERY THREE YEARS, by a licensed plumbing contractor
7. Write down the blower RPM value. It should be within 200 RPM of or authorized inspection agency, to ensure that the product
the value listed in the table below.
has not been affected by corrosive water conditions and
to ensure that the valve and discharge line have not been
8. Set the firing rate to High (high fire).
9. Write down the blower RPM value. It should be within 200 RPM of altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components
the value given in the table below.
time, rendering the valve inoperative. Such conditions
10. If any of the values are outside the ranges listed in the previous steps, over
are not detectable unless the valve and its components are
contact the factory for technical assistance.
physically removed and inspected. This inspection must
&IGURE Blower speeds for altitudes up to 5,500 feet (factory
setting) and high altitude (over 5,500 ft)
,OW lRE
)GNITION
(IGH lRE
-ODEL
3LIM&IT n
Factory
setting
High
altitude
Factory
setting
High
altitude
550
1300
1900
2500
2800
5725
5950
750
1300
1825
2350
2650
5275
5500
Factory Maximum
setting
setting
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.
only be conducted by a plumbing contractor or authorized
inspection agency — not by the owner. Failure to reinspect the
boiler relief valve as directed could result in unsafe pressure
buildup, which can result in severe personal injury, death or
substantial property damage.
Following installation, the valve lever must be operated AT
LEAST ONCE A YEAR to ensure that waterways are clear.
Certain naturally occurring mineral deposits may adhere to
the valve, rendering it inoperative. When manually operating
the lever, water will discharge and precautions must be taken
to avoid contact with hot water and to avoid water damage.
Before operating lever, check to see that a discharge line is
connected to this valve directing the flow of hot water from
the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water flows, valve is inoperative.
Shut down boiler until a new relief valve has been installed.
2. If the relief valve weeps or will not seat properly, replace
the relief valve. Ensure that the reason for relief valve
weeping is the valve and not over-pressurization of the
system due to expansion tank waterlogging or undersizing.
Multiple Boiler Running
Review with owner
1. Generate a call for heat on a Network Priority or a Local Priority
a.
Local Priority—allows Force Rate only on the boiler with the
call for heat. Follow Single Boiler procedure, above.
b. Network Priority—allows Force Rate on any boiler in the network. Follow procedure outline below in steps 2-5.
2. On the Master boiler, navigate to Manual Test Mode screen under
DIAGNOSTICS menu. Select desired boiler to be tested.
3. The Manual Test Mode screen will automatically appear on the boiler
you selected. On the selected boiler’s control, press ENTER and select
the desired FORCE RATE (HIGH, MED, OR LOW).
1. Review the User’s Information Manual with the owner.
2. Emphasize the need to perform the maintenance schedule specified in the User’s Information Manual (and in
this manual as well).
3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual
behavior.
4. Remind the owner to follow the proper shutdown procedure and to schedule an annual startup at the beginning
of the next heating season.
Part number 550-100-168/0516
95
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Troubleshooting
Reinstall boiler jacket front door
Before servicing and making connections . . .
!,7!93 452. 0/7%2 /&& 4/ 4(% "/),%2 4/
02%6%.4 %,%#42)#!, 352'%3 7()#( #!.
$!-!'% "/),%2 #/-0/.%.43
Reinstall boiler jacket front door after
servicing. The boiler front door must be
securely fastened to the boiler to prevent
boiler from drawing air from inside the
boiler room. This is particularly important if the boiler is located in the same
room as other appliances. Failure to keep
the door securely fastened could result in
severe personal injury or death.
%,%#42)#!, 3(/#+ (!:!2$ — The boiler ON/
OFF switch does not turn off all power to the boiler.
452. /&& !,, 0/7%2 4/ 4(% "/),%2 7(%.
3%26)#).'. Internal wiring is still powered when
the switch is off.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to boiler
before servicing. Failure to comply could result in
severe personal injury, death or substantial property
damage.
Never jumper (bypass) any device except for momentary testing. Severe personal injury, death or substantial property damage can result.
Before troubleshooting:
1. See Figure 82 for tools recommended for troubleshooting SlimFit boilers.
2. Check for 120 VAC (minimum 102 VAC to maximum 132 VAC) to boiler.
3. Check the Control’s last three lockout histories.
a. See Figure 68, page 78 for access information.
#0 NUMBER
Before calling, always complete
the “3LIM&IT 'AS $ATA #OLLEC
TION 3HEET” (page 124). Record
the boiler size and CP number
(located on the left side of the
control box, shown at right).
b. Scroll down to DIAGNOSTICS and press the
enter key.
c. Scroll down to PAST ERRORS and press the
enter key.
d. Record the first four data records and then
highlight the history record you want to view.
e. Follow information at the bottom of the screen
to navigate through your lockout histories.
&IGURE Tools for troubleshooting
96
4OOLS NEEDED FOR TROUBLESHOOTING
0URPOSE
#2 Phillips Screwdriver
Remove 4 screws to remove the top front cover
Control Screwdriver or 1/16" flat blade screwdriver
Used for wiring on terminal blocks for the Control (comes with boiler)
3/16" Allen Wrench (Hex Key)
To remove gas valve pressure tap plugs
3/8" Wrench
To remove gas pressure tap plug
13 mm Nut driver/ratchet
To remove the heat exchanger cover plate, mixing tube or blower
3 mm Allen wrench (Hex Key)
To adjust gas valve throttle
4 mm Allen wrench (Hex Key)
To add orifice to change from natural to propane
5 mm Allen wrench (Hex Key)
To disassemble venturi from blower (blower plate access)
13 mm wrench
To access combustion system and heat exchanger assembly, blower or mixing tube
Multimeter
To take measurement readings on sensors and electrical components
Manometer (Incline or digital)
To measure the gas pressure coming to the boiler.
Combustion analyzer (Digital preferred)
For combustion testing.
Contact thermometer
For checking surface temperatures of heat exchanger and pipes
T40 torx
For gas valve offset adjustment
8 mm wrench
For gas piping to venturi
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Troubleshooting (continued)
Check the following:
1. Make sure heat demand is calling for heat and contacts (including appropriate zone controls) are closed. Check for 24
VAC between thermostat wire nuts and ground.
2. Make sure all external limit controls are either installed (and
closed) or temporarily jumpered for testing.
3. Make sure that connectors to control module are securely
plugged in at module and originating control.
4. Gas pressures as specified on page 49 (natural gas) or
(propane).
Always check Control module fuses
ALWAYS check control module fuses before replacing control module or any major components
(blower, etc.). If one of these fuses is blown, it can
prevent control module or other components
from operating.
1. Turn OFF power to boiler at external line switch.
2. Remove jacket door and jacket top panel. Rotate the swingaway control panel forward to expose the Control module
and Expansion module.
3. Remove and inspect the two (2) Control fuses and the Expansion module fuse (located as shown below).
1
Do not jumper fuse or replace with any fuse except
as specified. Failure to comply could result in severe
personal injury, death or substantial property damage.
5. Reinstall jacket top panel and boiler jacket door after checking the fuses.
6. Restore power to boiler at external line switch and verify boiler
operation after completing boiler service.
Checking temperature sensors
1. The boiler temperature sensors (flue, outdoor, boiler out,
boiler in, heat exchanger and system) are all resistance-type
devices.
2. Figure 83 shows the correct value for the sensor at various
temperatures.
3. Use the resistance values at 32°F, 60°F, 70°F and 212°F to
measure the sensor resistance at known temperatures (freezing point, room temperature and sea level boiling point). For
freezing point and boiling point, insert the sensor in water at
that temperature. Use an ohmmeter to read resistance value.
4. To check whether the control module is correctly sensing
temperature, you can use a resistance decade box. Connect
the decade box temporarily in place of a sensor and read
the corresponding temperature on the Control display. The
temperature should be close to the value corresponding to
the input resistance.
&IGURE Sensor resistance values
Sensor resistance values
2
Temp
(°F)
1
4. If necessary, replace the fuse:
a. Item 1 - Low voltage circuit fuse is a 3-amp fast-blow
(Littelfuse 0287003).
Sensor ohms
Temp
(°F)
Sensor ohms
Min
Max
Min
Max
32
34265
37871
120
4517
4992
40
27834
30764
130
3698
4088
50
21630
23907
140
3043
3364
60
16944
18727
150
2517
2782
70
13372
14780
160
2091
2311
80
10629
11747
170
1744
1928
90
8504
9399
180
1461
1615
100
6847
7568
190
1229
1359
110
5545
6129
200
1038
1147
b. Item 2 - Line voltage circuit fuse is a 12-amp fast-blow
(Littelfuse 0314012 MXP or Bussman ABC-12-R).
Part number 550-100-168/0516
97
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
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 automatic reset conditions and manual reset
conditions. See Figure 58, page 70 for information
available on the Control display.
2. Figure 84 shows the screen behavior during an
automatic or manual reset condition. The table
&IGURE 98
below the display illustration lists manual reset conditions and how
to reset from them.
3. Figure 85, page 99 lists conditions that will cause the control to display
a constant red screen. The boiler will automatically restart if the condition self-corrects or the technician uses the Control’s manual reset
screens to reset.
Control display toggles when in lockout, with screen flashing red to gray
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Troubleshooting (continued)
&IGURE Troubleshooting suggestions for SlimFit boilers
RESET TO FACTORY DEFAULT
1. Selecting this will prompt the user to hold the enter button
for a specified length of time. Upon completion, this will
reset the control settings back to factory installed settings.
ONCE THIS IS CHOSEN, PREVIOUS SETTINGS CANNOT BE RECOVERED. ENSURE THIS ACTION IS
TRULY DESIRED BEFORE CONTINUING.
2. Reset to Factory Default can be found on the BOILER
SETTINGS menu, see Figure 62, page 73.
Control Error Condition Log
The Control is able to record information about the boiler’s condition at the time of the three previous faults or errors. This information is available to view in Contractor Menus under “DIAGNOSTICS” by selecting “PAST ERRORS.” The control will display
the following information:
Information
Description
Action
Control Fault
Records number
Select and press the enter key to reset this count
Ignition Retries
Displays the number of ignition attempts in the current
ignition sequence.
Manual Reset Count
Records number of lockouts that required a manual reset
since this count was last cleared.
Select and press the enter key to reset this count
Auto Reset Count
Records number of lockouts that have automatically reset
since this count was last cleared.
Select and press the enter key to reset this count
Lockout History 1
Details of present or last recorded lockout
Select and press the enter key for more details
Lockout History 2
Details of boiler during the second oldest lockout still in
memory
Select and press the enter key for more details
Lockout History 3
Details of boiler during the oldest lockout still in memory
Select and press the enter key for more details
How to read the last 3 lockout histories:
1. Scroll down to “DIAGNOSTICS” and press the
enter key (Square Key in center)
2. Scroll down to “ERRORS” and press the enter key
(Square Key in center)
3. Scroll down to “LOCKOUT HISTORY #” and press
the enter key.
4. Scroll to choose the either “MANUAL RESET” or
“AUTO RESET” and press the enter key to display
the fault condition that was recorded.
How to clear all lockout histories:
Part number 550-100-168/0516
1.
5. Press the left arrow key to return to the LOCKOUT
HISTORY # screen. Scroll up or down to highlight
other choices and press the enter key to view the
details of the boiler’s condition when the lockout
was recorded.
6. TO CLEAR ALL LOCKOUT HISTORIES: While on the
“ERRORS” screen, hold the Left and Right arrow
buttons simultaneously for 5 seconds.
While on the “PAST ERRORS” screen, hold the
Left and Right arrow buttons simultaneously
for 7 seconds.
99
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Troubleshooting (continued)
&IGURE Troubleshooting suggestions for SlimFit boilers (continued)
Control Fault Displays, Diagnostics and Suggested Corrective Actions
Display
Condition
Nothing shown Control is not receiving 24V
on display
power.
screen and boiler
will not respond
to call for heat
Nothing shown Control is not receiving 24V
on display
power.
screen and boiler
will not respond
to call for heat
Nothing is
Control is not receiving 120V
shown in display power.
screen and no
other boiler
components are
operating
Diagnostics
Corrective Action(s)
Check wiring for short circuit or
incorrect wiring.
Correct wiring per wiring diagram including connection of transformer
to the control.
Check 3-amp low voltage fuse
on control shown on page 97.
Replace fuse with proper part found in replacement part section of this
manual. If fuse blows again recheck wiring per diagram.
Check transformer connection
to the control per wiring
diagram. Check for 24V output
of transformer.
Replace transformer if it is receiving 120VAC, but not outputting 24VAC.
Check wiring for short circuit or
incorrect wiring.
Correct wiring per wiring diagram including connection of transformer
to the control.
Check 3-amp low voltage fuse
on control shown on page 97.
Replace fuse with proper part found in replacement part section of this
manual. If fuse blows again recheck wiring per diagram.
Check transformer connection
to the control per wiring
diagram. Check for 24V output
of transformer.
Replace transformer if it is receiving 120VAC, but not outputting 24VAC.
Check service switch and/or
circuit breaker to boiler is turned
on.
Turn on service switch to power boiler.
Is there 120 VAC at the service
switch?
Troubleshoot and correct the power supply to the service switch.
Check for 120 VAC at the line
voltage terminal block located
inside the top left electrical
compartment.
Correct wiring inside the control pod using the wiring diagram in this
manual.
Inspect 12-amp fuse as shown
Replace the fuse with proper part found in the replacement part section
on page 97. Replace if necessary. of this manual. If fuse blows again recheck wiring per diagram.
Nothing is
shown on
display screen,
but boiler is
operating
Occurs if the communication
is lost from the control to the
display.
or
Display contrast needs to be
adjusted.
TEMP RISE TOO
QUICKLY
DISPLAY COMM
Fault
100
Occurs if supply water
temperature in heat exchanger
rises faster than 2º F per
second during the first two
minutes the burner is on.
Occurs if display
communications out for 30
seconds.
Check for loose connections
and proper pin alignment/
engagement on the control's
plug P9, Pump/Com board P6 +
J1, and the back of the display
circuit board.
Check for continuity on the wire harness from the display to the control.
See repair parts section for proper replacement part.
Cycle power off and on using
boiler power switch and check
for operation.
Replace with new display module. See repair parts section for proper
replacement part.
Look at the screen from other
angles.
Power cycle the boiler, wait about 45 seconds then Press and hold
the Enter button. While holding the Enter button, tap the up or down
buttons to adjust the contrast level. If this does not work replace display.
Automatically resets after 1
minute delay or using manual
reset on display.
Verify water pipe is installed correctly per instructions in this manual.
Manual reset is necessary after 5
automatic resets have occurred
during the same Priority heat
demand. Reset using manual
reset screen on display.
Verify proper circulator and speed for boiler size and system
requirements.
See message displayed TEMPERATURE SENSOR and follow procedure for
loose connections.
Automatically resets when
Check for a loose connection at the molex plug on the control and
communication is re-established. connection on the back of the display.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Troubleshooting (continued)
&IGURE Troubleshooting suggestions for SlimFit boilers (continued)
Control Fault Displays, Diagnostics and Suggested Corrective Actions
Display
LOW WTR
CUTOFF OPEN
Condition
Occurs if internal low water
cutoff contacts open.
Diagnostics
Automatic reset occurs if
contacts are open at least one
second, but less than 5 seconds.
Manual reset of control if
contacts are open longer than
5 seconds.
SUPPLY 58° F >
RETURN
Boiler Out temperature
has exceeded the Boiler In
temperature by more than
58º F.
Automatically resets after 30
second delay when conditions
no longer exist or using manual
reset on display.
Corrective Action(s)
Check for low water condition in system. Repair system as necessary
refer to piping section of this manual.
If low water condition does not exist, check Diagnostics — Inputs screen
to view status of Low Water Cutoff. If shown as OPEN check wiring
between LWCO and control. If wiring is alright, remove LWCO and Clean
probe. If problem still exist, then replace the LWCO.
Low water cutoff indicator light codes:
GREEN on = Normal operation
GREEN + AMBER on = Service probe soon
RED + AMBER = Control locked out
RED blinking = LWCO component failure
When the service indicator light code occurs, schedule a
service appointment as soon as possible to avoid the boiler
shutting down on low water lockout. To service the probe,
shut off all power supplies to the boiler. Close the boiler
isolation valves. Then drain enough water from the boiler to
allow removing the low water cutoff. Inspect the probe. Clean
if necessary to remove scale accumulation. Reinstall the low
water cutoff and restore boiler to operation. If the problem
persists, replace the low water cutoff probe.
Verify water pipe is installed correctly per instructions in this manual.
Verify proper circulator and speed for boiler size and system
requirements.
See message displayed TEMPERATURE SENSOR and follow procedure for
loose connections.
RETURN >
SUPPLY
Occurs if a return water
temperature is greater than
the corresponding supply
temperature by 10º F or more.
Automatically resets when
condition no longer exists.
Verify proper flow direction of the boiler circulator.
Verify proper placement of system sensors for single or multiple boiler
system. System sensors should be on system piping not on the boiler
loop.
Verify sensors are wired to correct terminal locations.
System sensors may need to be located further away from the boiler
loop connection to the system, if proximity to the boiler loop is causing
sensors to be heated inaccurately.
SUPPLY WATER
TEMPERATURE
TOO HIGH
Occurs when the System
Supply temperature goes
above 200º F when the
burner is running.
Automatically resets when
Supply temperature goes below
200º F.
Verify proper flow direction of the boiler circulator. This circulator must be
installed to push water through the system.
TEMPERATURE
SENSOR FAULT
Occurs if a temperature
sensor has electrically shorted
(SHORT) or has become
disconnected (OPEN).
Will automatically reset if the
condition clears.
Check all the temperature readings of the boiler on the DIAGNOSTICS TEMPERATURES menu to determine if any sensors are currently displayed
as SHORT or OPEN. Compare this to the boiler temperatures recorded
in the DIAGNOSTICS - ERRORS - LOCKOUT HISTORY # - TEMPERATURES
during the last several lockout conditions.
Determine which sensors are suspect and measure their resistance
value and compare it to the values shown in Figure 81, page 94. If the
resistance values are incorrect replace the temperature sensor. Refer to
repair parts section for proper part number.
Check wire harness for loose connections and pin engagement at sensor
connection, chassis mount connection through control housing, and
the control. Unplug connection at sensor and at control and check
continuity between ends.
If problem persists after checking items above, replace control. Refer to
repair parts section for kit number.
Occurs if dual temperature
sensors values have spread by
more that 10º F if the burner
is on.
Part number 550-100-168/0516
Automatically resets when
sensors are within 10º F.
Follow procedure for above for SHORT and OPEN sensor conditions
to properly diagnose sensor. If measured resistance values of sensors
convert to temperatures separated by more than 10º F replace the
sensor.
101
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Troubleshooting (continued)
&IGURE Troubleshooting suggestions for SlimFit boilers (continued)
Display
LIMIT OPEN
HIGH TEMP
LIMIT
Condition
Occurs if manual or automatic
reset l imit op ens.
Boiler temperature sensor
reached High Temp Limit
setting (no higher than 200° F).
Diagnostics
Corrective Action(s)
Automatic external limit will
reset 2½ minutes after external
limit device closes.
Is there an external safety device connected? If yes, trouble shoot the
external limit to determine and correct the cause that opened the limit.
Also check for loose wiring connections.
Manual limit fault must be reset
by choosing Manual Reset on
the display.
Remove the top right Control tray cover and inspect the connector.
Ensure a jumper is installed across the MAN LIMIT terminals if not using a
manual reset external limit.
Ensure a jumper is installed across the AUTO LIMIT terminals if not using
a automatic reset external limit.
Reset using manual reset screen
on display.
Verify that high limit setting is at least 10° F above the maximum target
temperature plus the off differential.
Verify all isolation valves are open and circulators are programmed into
the control properly.
The boiler circulator output and System Pump/Aux. output can be
configured to turn on or off with each priority. Refer to the Control Setup
section to configure these properly for the system.
Verify water pipe is installed correctly per instructions in this manual.
Verify proper circulator sizing for boiler size and system requirements.
See message displayed TEMPERATURE SENSOR and follow procedure for
loose connections.
FLAME FAULT
Occurs if flame is detected
when there should be no
flame.
Reset using manual reset screen
on display.
Burner may be operating too hot due to incorrect combustion. Inspect
flame and conduct combustion test.
Force boiler into high fire. Check flue gases with combustion analyzer
and correct using the maintenance and startup procedure in this manual.
Verify FLAME SIGNAL value quickly goes to zero on the DIAGNOSTICS INPUTS screen when the gas valve closes.
Check for flame at burner via flame current with burner off. Turn boiler
off and watch flame through observation port. If flame continues after
shut down replace gas valve.
BLOWER FAULT
Blower unable to reach
required speed or does not
reach 0 RPM when turned off.
Reset using manual reset screen
on display; Control will check
again after 1 hour and will
automatically restart if condition
is corrected.
Check wire harness for loose connections and pin engagement at
blower connections, chassis mount connection through control housing,
and control. Unplug connection at blower and at control and check
continuity between ends. Blower is connected to both low voltage and
line voltage harness.
Check Diagnostics - Inputs screen with boiler in standby mode and
blower not running. If BLOWER SPEED is not 0 RPM then replace blower.
If blower does not rotate during ignition sequence check for 120V power
at blower connection. If 120 VAC power at blower motor and it doesn't
start replace blower. Check power at control. If 120VAC is not present
at control when boiler is powered replace Control. Refer to repair parts
section.
102
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Troubleshooting (continued)
&IGURE Troubleshooting suggestions for SlimFit boilers (continued)
Display
IGNITION
FAULT
Condition
Diagnostics
Corrective Action(s)
Boiler went through 5 ignition
attempts and never detected
flame or flame sense value
never reached minimum
threshold for boiler model.
Automatically resets after 1 hour
or can be reset by performing
manual reset on boiler.
Check condensate trap for blockage allowing condensate to accumulate
inside heat exchanger.
Check ignition cable connection.
Fouled, worn, bent, or faulty igniter.
Fouled igniters can be cleaned for additional use with steel wool.
Worn or badly fouled igniters should be replaced with the proper repair
part.
Igniter rods should be parallel with a 3.5 mm (0.138 in) spark gap.
NOTICE: Thin white deposits on the igniter are typical, but brown or
black deposits could be the result of flue gas recirculation. Thoroughly
inspect the venting system and termination for the possibility of leakage
or flue gas feedback into the air line.
Dirty burner and/or heat exchanger will cause high back pressure and
poor ignition.
Follow procedure in maintenance section of this manual to clean burner
and heat exchanger. Visual inspection of flueways may not be sufficient
to diagnose condition.
Check combustion settings on high and low fire and adjust per setup
instructions if necessary.
Check incoming gas pressure with boiler off and at high fire. Adjust
within limits on rating label.
Verify correct boiler model and altitude is selected in control and correct
elevation must be entered when operating above 2,00 feet.
Check ignition cable resistance. Should measure 1000 Ohms (+/- 50
Ohms).
Check for flue pipe and intake pipe restrictions or blockage.
Check burner fasteners and gaskets.
Check venturi gaskets and proper venturi. (Propane models use different
venturi’s).
AIR PRESSURE
Switch Open
Occurs when Air Pressure
connection is open.
Reset using Manual Reset
screen on display.
High pressure in the exhaust
pipe or high vacuum in the
boiler intake or cabinet has
caused the air switch to open.
The switch is closed in normal
operating conditions.
Check boiler size selected in control against boiler rating label. Correct if
necessary to select the proper boiler size.
Check exhaust and intake pipe for restrictions or blockage.
Check condensate drain for blockage. If condensate is unable to drain
out of the boiler it can begin to block the flow of exhaust gases. Clean
the condensate collection area of the base and condensate trap. Refill
trap with fresh water.
Check the P7 connection as seen on Figures 52, page 60 &
Figure 53, page 62. Check the connections on the pressure switch.
Part number 550-100-168/0516
103
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Troubleshooting (continued)
&IGURE Troubleshooting suggestions for SlimFit boilers (continued)
Display
GAS PRESSURE
SW FAULT
Condition
Gas pressure switch is open
(high or low).
Diagnostics
Corrective Action(s)
Either the low gas pressure
switch or high gas pressure
switch has opened due to
incorrect gas pressure being
supplied to the boiler. Remove
front door of boiler and look at
pressure switches. The upper
switch is the high gas pressure
switch and the lower one is a low
gas pressure switch. Whichever
switch has locked-out will
have an indicator light on.
Switches can be reset by
pushing on plastic cover
in the middle of the dial as
indicated on the switch.
Control will also need reset
using display after gas pressure
switch has been reset.
Check gas pressure at tee mounted behind gas pressure switches during
high and low fire and boiler off. Pressure should always be with limits on
rating label. Undersized gas supply pipes or regulators may cause low
gas pressure issues while the boiler is operating and possibly high gas
pressure when the boiler shuts down.
Insure the pressure regulator in the gas supply line is a lockup-type.
Ensure gas pressure switch settings are correct.
Low Pressure Switch Setting = 2 inches H2O
High Pressure Switch Setting = 14 inches H2O
HW FAULT
EXPANSION
BRD
Expansion Control Board
hardware has failed.
Expansion Control Board has
detected an issue with it’s
hardware and has locked out.
Requires a manual reset.
Check boiler size selected in Control against boiler rating label. Correct if
necessary to select the proper boiler size.
GV FAULT
EXPANSION
BRD
Gas valve output of the
Expansion module.
Expansion Control Board has
detected an issue with the gas
valve circuit. Requires a manual
reset.
Check the wire harnesses between the Control, Expansion module, and
gas valve.
EXP BOARD
COM FAULT
Expansion Control Board
communication fault.
Communication has been lost
between the Control and the
Expansion Control Board.
Check the communication wire harness between the two controls.
PS Fault Exp.
Board
Pressure switch issue
detected on expansion board.
Unit receives manual reset.
Check connections to expansion board.
Check air and gas pressure switches
Hardware Fault
Occurs when micro-controllers Check for hardware damages.
on main board have a RAM or
ROM error, or communication
is cut off.
(ARDWARE
&AULT 8
The control has detected a
problem with its gas valve
output circuit.
RAM or ROM errors can be reset with the manual reset option.
If problems persist, replace main board.
Auto reset if condition is clear Check for physical damages.
after lockout, then 1 hour Check connections to gas valve and gas pressure.
automatic reset if condition clear, If problem persists, replace main board.
then manual reset required.
Proof of Closure connections
#LOSURE
3WITCH &AULT on P7 Pins 2 and 3 are open
Soft lockout for 3 ½ minutes
boiler retries. Each consecutive
failure adds 1 minute to lockout
time, up to 6 ½ minutes
maximum.
None – Check jumper on correct pins and secure connection.
Flow switch attached – Check correct pump is on, check wiring to flow
switch, and check switch is closing.
CAD – Check voltage to damper. Check damper is opening.
OUTDOOR
SENSOR ERROR
Will automatically reset if the
condition clears.
Determine which sensors are suspect and measure their resistance
value and compare it to the values shown in Figure 83, page 97. If the
resistance values are incorrect replace the temperature sensor. Refer to
repair parts section for proper part number.
Outdoor temperature sensor
short or OPEN.
Warning only. Supply Max is
targeted until ODT is restored, if
used for target adjustment.
Check wire harness for loose connections and pin engagement at sensor
connection, chassis mount connection through control housing, and
the control. Unplug connection at sensor and at control and check
continuity between ends.
If problem persists after checking items above, replace control. Refer to
repair parts section for kit number.
&LUE 4EMP
4OO (IGH
Occurs if flue temperature
sensor exceeds 210°F
(Warning) or 220°F (Lockout).
Automatic reset occurs if
temperature drops below 210°F
for 2 ½ minutes.
Follow procedure above for SHORT and OPEN sensor conditions
to properly diagnose sensor. In addition inspect heat exchanger
combustion chamber and flue-ways for abnormal wear and buildup.
Manual reset is required if the
temperature rises above 220°F.
Reset using manual reset screen
on display.
Inspect vent system for abnormal wear or damage.
Contact Weil-McLain Technical Support.
104
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Maintenance
Disconnect power
Electrical shock hazard — Disconnect all electrical
power to the boiler before attempting maintenance
procedures. Failure to complete could result in severe personal injury, death or substantial property
damage.
Install boiler jacket front door after
startup or servicing
Cleaning the heat exchanger — pin
side when required
1. Shut down boiler:
a. Follow “To Turn Off Gas to Appliance” instructions
on boiler and Lighting instructions.
b. Do not drain boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in
system, do not drain.
2. Allow time for boiler to cool to room temperature if it
has been firing.
Reinstall boiler jacket front door after start-up or
servicing. The boiler front door must be securely
fastened to the boiler to prevent boiler from drawing
air from inside the boiler room. This is particularly
important if the boiler is located in the same room
as other appliances.
3. Rotate the two rotary latches on the front door. Tilt
the top of the door forward, then lift up. Use a 13-mm
wrench or socket to remove the nuts on the front cover
plate and remove the plate. Use the cleanout plug in the
flue pipe to rinse debris into the condensate drain. Flush
the condensate drain, then refill.
Inspect boiler jacket door gaskets. Gaskets must be
in good condition, with no tears or gaps. Replace if
necessary.
4. Follow the applicable procedures under “Accessing &
cleaning the heat exchanger,” page 106.
Failure to keep the door securely sealed and fastened
could result in severe personal injury or death.
Clean the cast aluminum heat exchanger
when required — water side
Perform start-up and check/out
Removing and reinstalling components can change
boiler behavior. After any maintenance procedure,
you must prove the boiler is operating correctly. To
do so, follow the complete procedure for boiler and
system start-up, beginning on page 85. Failure to
comply could result in severe personal injury, death
or substantial property damage.
1. In order for the efficiency of boilers to increase beyond
the condensing limit, new materials have been introduced for the heat exchanger, including aluminum.
2. Aluminum has excellent heat transfer characteristics
and is light in weight.
3. These new materials also require cleaning solutions
that differ from those used in conventional cast iron
and steel boilers.
One common cleaning method that #!../4
be used with systems containing aluminum is
a solution of trisodium phosphate, commonly
referred to as “TSP.”
General maintenance
1. Oil motors in system requiring regular oiling.
2. See Oiled bearing circulators for motor oiling procedures.
Oiled bearing circulators
1. Check circulators in the system. Oil any circulators requiring oil,
following circulator manufacturer’s instructions. Over-oiling will
damage the circulator.
Part number 550-100-168/0516
The reason that trisodium phosphate cannot
be used is that the cleaning solution has a very
high pH level — while removing the scale in
the system, it also removes the natural protective oxide layer from the aluminum. The
oxide layer will reform, but if small amounts
of the trisodium phosphate remain in the
system, the chemical will continue to remove
the protective oxide layer, leading to reduced
heat exchanger life.
4. Use ONLY the cleaning product available from WeilMcLain, Sentinel X400. See the Repair Parts section at
the end of this manual for ordering information.
105
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Maintenance (continued)
Accessing & cleaning the heat
exchanger
Remove heat exchanger cover plate
and burner
1. Close the external manual gas valve.
2. Disconnect all power to the boiler.
3. Allow the boiler to cool if it has been operating.
4. Use a 13-mm wrench or socket to remove the nuts
that secure the heat exchanger cover plate to the
heat exchanger (Figure 86, page 107).
5. Follow the procedure on page 94 to remove the
burner. Disconnect wire harnesses as required to
move the mixing tube and blower assembly out
of the way.
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation. Always disconnect power to
boiler before servicing. Failure to comply
could result in severe personal injury,
death or substantial property damage.
If the silicone cord gasket has been damaged or stretched,
replace it before placing the boiler back in operation. To
install the silicone cord gasket:
s 7HEN INSTALLING THE SILICONE CORD GASKET THE SEAM
should start at the top middle of the gasket groove. See
Figure 86, page 107.
s #AREFULLY PLACE THE CORD IN THE GROOVE ALL AROUND THE
cleanout plate.
s $O NOT SPLICE PIECES TOGETHER 4HE GASKET MUST BE
installed as one piece.
s 7HEN INSERTING THE GASKET DO NOT STRETCH THE CORD OR
stretch around corners. This could cause the cord not to
seal correctly, resulting in possible flue gas or condensate
leakage.
Failure to comply could result in severe personal injury,
death or substantial property damage.
6. Remove the flue inspection cover.
Use heat exchanger cleaning tool
1. Use the Heat Exchanger Cleaning Tool (supplied
with the boiler) or a piece of 20-gauge or lighter
sheet metal ¾” wide by about 18 inches long to
loosen deposits.
2. Slide the cleaning tool through the heat exchanger
pins in the three directions shown in Figure 87,
page 107.
3. Vacuum most of the debris out of the base through
the flue inspection opening.
Water spray the heat exchanger
1. Disconnect the condensate line at the bottom of
the heat exchanger so debris will not clog the trap.
a. Loosen the hose clamps at both ends of the
condensate line.
b. Remove the line and place a pan under the trap
connection.
2. Use the burner opening to spray water down onto
the heat exchanger pins. Continue spraying until all
debris on the pins has been flushed into the base.
a. Spray water into the flue inspection opening
to flush remaining sediment to the condensate
outlet.
b. Spray water through the condensate line to
clean it thoroughly.
c. Remove the pan and re-install the condensate
line.
d. Re-install the flue inspection plug.
106
Inspect cover plate gasket
1. Inspect the silicone cord heat exchanger cover plate gasket. Replace if
damaged.
2. Make sure the cover plate gasket is in the groove of the heat exchanger.
3. Inspect the cover plate insulation, replace if damaged.
Re-install cover plate
1. Re-install the cover plate following the sequence shown in the appropriate illustration, Figure 88, page 107 or Figure 89, page 107.
2. Re-install the hex head nuts on the cover plate mounting studs and
tighten in the staggered pattern shown for the boiler model (Figure 88,
page 107 for SF-550 or Figure 89, page 107 for SF-750) until the cover
plate is uniformly tightened.
Gradually tighten the cover plate nuts in the sequence shown.
Torque to 18 N-m/160 in-lbs/13 ft-lbs.
Re-install burner, mixing tube and blower assembly
1. Follow the procedure on page 94 to re-install the burner and other
components.
2. Reconnect wiring, including the ignitor ground wire connection to the
top ignitor mounting screw.
Restart and test the boiler
1. Restore gas supply and power to the boiler.
2. Start the boiler and verify operation following the procedures given
in this manual.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Maintenance (continued)
&IGURE Removing heat exchanger cover plate
Gasket
&IGURE .UT TIGHTENING SEQUENCE ˆ 3& 'RADUALLY TIGHTEN THE NUTS REPEATING
THE SEQUENCE SHOWN BELOW UNTIL THE
TORQUE REACHES INCH POUNDS INCH POUNDS . M . M
Silicone cord starts and
finishes at the top center
10
8
1
3
5
6
11
7
12
9
2
4
Insulation
&IGURE .UT TIGHTENING SEQUENCE ˆ 3& 'RADUALLY TIGHTEN THE NUTS REPEATING
THE SEQUENCE SHOWN BELOW UNTIL THE
TORQUE REACHES INCH POUNDS INCH POUNDS . M . M
&IGURE Cleaning heat exchanger with cleaning tool
45° Down
12
10
8
1
3
5
6
13
Horizontal
7
14
11
9
2
4
45° Up
Part number 550-100-168/0516
107
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts
Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model
and size and include description and part number of replacement part. Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation.
Weil-McLain part numbers are found in Weil-McLain Boilers and Controls Repair Parts Lists.
4HE BOILER CONTAINS CERAMIC lBER MATERIALS. Use care when handling these materials per instructions on page 91
of this manual. Failure to comply could result in severe personal injury.
Reinstall boiler jacket front door after startup or servicing
Inspect boiler jacket front door gaskets and reinstall boiler jacket front door after start or servicing. The boiler front
door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room. This is
particularly important if the boiler is located in the same room as other appliances. Failure to keep the door securely
fastened could result in severe personal injury or death.
&IGURE Propane conversion kits
Propane conversion must follow the instructions in this manual. Refer to page 8 for details.
.ATURAL TO PROPANE CONVERSION KITS ˆ PROVIDED WITH BOILER
3EA LEVEL UP TO FEET AND (IGH ALTITUDE OVER FEET
108
-ODEL
+IT PART +IT INCLUDES
)NSTRUCTIONS
3& 383-600-074
,0 0ROPANE ORIlCE
0ROPANE CONVERSION LABEL
See page 8.
3& 383-600-075
,0 0ROPANE ORIlCE
,0 "LOWER ORIlCE PLATE
BLOWER ORIlCE PLATE GASKETS
0ROPANE CONVERSION LABEL
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Miscellaneous parts and kits
Item
Description
Part Number
1
Condensate neutralizer kit (up to 1000 MBH)
383-600-076
2
Heat exchanger cleaning tool
591-706-200
3
Pressure relief valve
4
Bird screen (1 each required for vent and air pipe termination)
6-inch (for 6-inch vent or air pipe)
8-inch (for 8-inch vent or air pipe)
5
6
CHEMICALS
Antifreeze, aluminum-safe, Sentinel X500 (1 gallon)
Antifreeze, aluminum-safe, Sentinel X500 (5 gallon)
Corrosion inhibitor, Sentinel X100 (one tube, 275 ml)
Inhibitor quick-test kit . . . . . . . . . . . . . . . .
Cleaner, Sentinel X400 (one tube, 275 ml). . . . . .
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560-907-633
560-907-634
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Annual maintenance kit (for SF-550 or SF-750) consisting of:
(1) ignitor
(1) ignitor gasket
(2) screws for ignitor
7
383-600-063
383-600-064
383-600-065
ASME 30 PSI, 3/4” NPT female
ASME 50 PSI, 3/4” NPT female
ASME 80 PSI, 3/4” NPT female
(2) washers for ignitor
(1) inhibitor test kit
(1) suppressor
383-600-079
(2) blower connection gaskets
(1) length of silicone cord for cleanout
plate
Vent adapter 6” for stainless steel vent pipe AL29-4C, Dura-Vent – FasNSeal™
Part number 550-100-168/0516
592-900-029
592-900-006
592-900-002
592-900-005
592-900-003
383-600-083
109
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Jacket parts
Item
Part Number for
SlimFit 550/750
Description
1
Jacket front door
383-600-052
2
Door seal
383-600-022
3
Handle (2 required)
383-500-611
4
Back Jacket
426-700-044
5
Jacket seal kit (base seal, door seal, grommets and gaskets)
383-600-053
6
Plastic top cover (includes cover, gaskets and hardware)
383-600-054
7
Inlet/outlet adapter
593-000-052
'O TO WWWWEIL MCLAINCOM TO LOCATE 7EIL -C,AIN DISTRIBUTORS
110
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Jacket parts
Part number 550-100-168/0516
111
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Heat exchanger
Item
Boiler
Models
Description
Part Number
1
5 section heat exchanger assembly kit (includes sections, o-rings, sealing cord
& hardware)
550
383-600-029
2
6 section heat exchanger assembly kit (includes sections, o-rings, sealing cord
& hardware)
750
383-600-028
3
Left end section replacement kit (includes section, o-rings, sealing cord and
hardware)
550 / 750
383-600-036
4
Intermediate section replacement kit (includes section, o-rings, sealing cord
and hardware)
550 / 750
383-600-037
5
Right end section replacement kit (includes section, o-rings, sealing cord and
hardware)
550 / 750
383-600-038
6
Section/manifold o-ring, 60-mm (single o-ring only)
550 / 750
590-318-039
7
5 section draw rod kit
550
560-134-510
8
6 section draw rod kit
750
560-134-511
9
5 section heat exchanger cover plate kit (includes plate, nuts, sealing cord,
insulation and silicone RTV sealant)
550
383-600-040
10
6 section heat exchanger cover plate kit (includes plate, nuts, sealing cord,
insulation and silicone RTV sealant)
750
383-600-041
11
5 section supply distribution tube kit (distribution tube, o-ring and nuts)
550
383-600-033
12
6 section supply distribution tube kit (distribution tube, o-ring and nuts)
750
383-600-032
13
5 section return distribution tube kit (distribution tube, o-rings and nuts)
550
383-600-031
14
6 section return distribution tube kit (distribution tube, o-rings and nuts)
750
383-600-030
15
Return manifold casting kit (includes manifold, o-ring and nuts)
550 / 750
383-600-034
17
Aluminum flue pipe
550 / 750
560-907-673
18
Plastic base assembly kit (includes base, sealing cord, silicone RTV sealant
and hardware)
550 / 750
383-600-026
19
Adapter Flue Pipe / Inlet-Air Bottom
550
750
593-000-053
593-000-054
20
Base seal kit (base sealing gasket cord)
550 / 750
383-600-021
21
Red silicone cord kit (cover plate and base)
550 / 750
383-600-020
22
Tube of silicone RTV, high temperature, red
550 / 750
513-000-001
23
Tube of silicone RTV, high adhesive, black
550 / 750
513-000-000
24
Return distribution tube o-ring, 45 mm
550 / 750
590-318-040
25
Heat exchanger o-ring replacement kit (Not shown) [includes (18) 60-mm
o-rings (Item 6); (2) 45-mm o-rings (Item 24); sealing cord; and silicone RTV
sealant]
550 / 750
383-600-039
'O TO WWWWEIL MCLAINCOM TO LOCATE 7EIL -C,AIN DISTRIBUTORS
112
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Heat exchanger
Part number 550-100-168/0516
113
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Piping
Item
Description
Boiler
Models
Part Number
1
Supply manifold kit (Includes items 5 through 8 and 10 through 14)
550 / 750
383-600-055
2
Return pipe kit (includes items 9 and 14)
550 / 750
383-600-035
3
Inlet gas pipe kit (includes items 16, 17, and 18)
550 / 750
383-600-056
4
Supply distribution pipe
5
Serrated-flange nut, M8-1.25 (four (4) required)
550 / 750
In Item 1
6
Supply distribution manifold, 2” NPT
550 / 750
In Item 1
7
Section/manifold o-ring, 60 mm (included in Item 1; also see Item 6, Figure 95,
page 113)
550 / 750
590-318-039
8
Supply/return pipe grommet, 2” NPT x 3½” diameter (included in Item 1)
550 / 750
562-248-747
9
P/T gauge pressure sensor line check valve
550 / 750
383-500-275
10
Plug, ½” NPT
550 / 750
In Item 1
11
Low water cut-off
550 / 750
383-600-069
12
P/T gauge temperature sensor well
550 / 750
383-500-270
13
Supply temperature sensor
14
Return pipe, 2” NPT
550 / 750
In Item 2
15
Inlet gas pipe with flange
550 / 750
In Item 3
16
Inlet gas pipe gasket (included in Item 3)
550 / 750
590-300-017
17
Screws, 3/8-16 x ½”, button head; washers, 3/8” SAE (4 of each required)
550 / 750
In Item 3
114
See Figure 95, page 113
See Figure 101, page 119
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Piping
Part number 550-100-168/0516
115
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Burner, blower, venturi and gas train
Item
Description
Part Number for
SlimFit 550/750
1
5 section burner replacement kit (includes burner, gasket and nuts)
383-600-044
2
6 section burner replacement kit (includes burner, gasket and nuts)
383-600-043
3
Blower assembly kit (includes blower, gasket, o-ring and hardware)
383-600-045
4
5 section venturi replacement kit (includes venturi, o-ring and gasket)
383-600-067
5
6 section venturi replacement kit (includes venturi, o-ring and gasket)
383-600-068
6
Venturi to gas pipe gasket
590-300-022
7
Gas valve replacement kit (includes gas valve only)
383-600-066
8
Gas valve to venturi piping kit (includes piping, gasket, o-ring and hardware)
383-600-046
9
O-Ring, gas valve to adapter pipe
590-318-042
10
Low gas pressure switch replacement kit (includes switch and nipple)
383-600-049
11
High gas pressure switch replacement kit (includes switch and nipple)
383-600-048
12
Gas pressure switch piping
383-600-047
13
Gas pressure switch harness (not shown)
383-600-059
14
Gas valve harness (not shown)
591-391-960
15
Flexible gas line
560-900-021
16
Air silencer
560-900-020
17
Inspection glass kit (includes retainer, glass, gasket and screws)
383-500-020
18
Ignition cable kit (not shown)
383-500-619
19
Ignition electrode kit (includes ignitor, gasket and hardware)
383-600-070
20
Venturi-to-blower o-ring (included in item 4 and item 5)
590-318-041
21
Blower outlet gasket (included in item 3)
590-300-018
22
Burner gasket (included in item 1 and item 2)
590-300-011
Blower orifice plate for SF-550 (used for both natural gas and propane)
383-600-078
23
Blower orifice plate for SF-750 (used only on SF-750 propane)
116
See propane conversion kit
(Figure 90, page 108)
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Burner, blower, venturi and gas train
Part number 550-100-168/0516
117
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Controls
Item
Part Number for
SlimFit 550/750
Description
1
3-amp, fast-blow ATO (5 fuses)
383-500-603
2
12-amp, slow-blow AG (5 fuses)
383 500 604
3
Control module
383-600-162
4
Kit - Service Conversion Series 1 to Series 2 (Includes items 3, 5, 6, 23, 24 & 27)
383-600-164
5
Expansion module
383-600-160
6
Display board assembly
383-600-159
7
Display bracket kit
383-600-042
8
Supply temperature sensor replacement kit, dual sensor (sensor only)
383-600-072
9
Return temperature sensor replacement kit, single sensor (sensor and bushing)
383-600-071
10
Outdoor temperature sensor
510-312-218
11
System temperature sensors
383-500-601
12
Flue Temperature sensor replacement kit (sensor and grommet)
383-500-600
13
Heat exchanger temperature sensor
383-500-602
14
On/off power switch
383-500-205
15
Transformer, 120v/24v
383-500-628
16
Pressure/temperature gauge assembly
570-218-054
17
120 volt, 3-wire receptacle, pre-wired
591-391-959
18
Air pressure switch kit (includes switch, tube and mounting screws)
383-600-073
19
Hose barb for air pressure switch sensing tube connection (not shown)
562-302-525
20
Air pressure switch sensing tube (included in item 18)
21
Blower power relay
570-350-230
22
SlimFit Control terminal block kit (not shown)
383-500-642
23
Control to Expansion Module wire harness, RS485 (not shown)
383-500-633
24
Expansion module to display harness, Cat-se RJ4S (not shown)
383-600-163
25
Upper line voltage wire harness (EP2, EP4, power input and blower relay) (not shown)
383-600-057
26
Low line voltage wire harness (not shown)
591-391-958
27
Upper low voltage wire harness (not shown)
383-600-158
28
Lower low voltage wire harness (P4 through P9 and other) (not shown)
591-391-956
29
Jumper for low voltage terminal blocks ( 5 jumpers) (not shown)
383-500-641
30
Flue temperature sensor gasket
590-318-011
In Item 18
'O TO WWWWEIL MCLAINCOM TO LOCATE 7EIL -C,AIN DISTRIBUTORS
118
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Replacement parts (continued)
&IGURE Controls
Part number 550-100-168/0516
119
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Dimensions
&IGURE Dimensional data
Notes
120
1
Boiler supply and return connections are both 2” NPT.
2
Circulator must be mounted in the return piping.
3
Relief valve is shipped loose.
See page 12 for mounting details. Relief valve mounts on supply pipe off of supply tee as shown.
4
Boiler gas connection, 1¼” NPT.
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Ratings — SlimFit Series 3 boilers
&IGURE Ratings and engineering data
DOE
AHRI Certified Ratings
Boiler
Model
Number
CSA
Input
Gross
Output
Net
Rating
Combustion
Efficiency
Thermal
Efficiency
Boiler
Water
Content
Vent/Air
Pipe Size
(inches)
Btuh (Note 3)
Btuh (Note 3)
Btuh (Note 1)
% (Note 2)
% (Note 2)
Gallons
(Note 4)
SF-550
550,000
517,000
450,000
94.7
93.9
5.5
6 or 8
SF-750
750,000
702,000
610,000
94.0
93.6
6.5
6 or 8
Notes
1
AHRI Net ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15. An additional
allowance should be made for unusual piping and pickup loads.
2
Combustion efficiency and thermal efficiency are based on AHRI testing procedure per BTS-2000.
3
Ratings shown are for sea level applications only. For altitudes above sea level, the SlimFit boiler requires no modifications
and automatically derates itself by approximately 4% per 1000 feet above sea level. For elevations over 5,500 feet, configure
the Control with HIGH ALTITUDE = YES.
SlimFit boilers can be direct vent or direct exhaust vented, either through a side wall or through roof, as instructed in this
manual and compliant with all local codes. SlimFit Boilers require special venting, consistent with Category IV boiler.
4
Category II, 8” venting requires 8” vent adapter, see pages 33-34.
Use only the vent materials and methods identified in this manual.
Part number 550-100-168/0516
121
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Ratings — multiple SlimFit Series 3 boilers
&IGURE Ratings and engineering data (see Figure 106 for notes)
Boilers
in system
Total
CSA
input
Input,
MBH
SF-550
Output,
MBH
Total
Net
Rating
MBH
Total
Boiler
H.P.
—
SF-750
2
2
3
3
4
4
5
5
6
6
7
7
8
8
122
Total
Gross
Output
Manifolded
combustion
air duct
size
Square
inches
Foundation size
Side-to-side
arrangement
Back-to-back
arrangement
(height 2” to 4”)
(height 2” to 4”)
Length
(inches)
Width
(inches)
1034
900
30.9
550
1500
1404
1220
41.9
750
1650
1551
1350
46.3
825
2250
2106
1830
62.9
1125
2200
2068
1800
61.8
1100
3000
2808
2440
83.9
1500
2750
2585
2250
77.2
1375
3750
3510
3050
104.9
1875
3300
3102
2700
92.7
1650
4500
4212
3660
125.8
2250
3850
3619
3150
108.1
1925
5250
4914
4270
146.8
2625
4400
4136
3600
123.6
2200
6000
5616
4880
167.8
3000
Width
(inches)
Note 1
Figure 26, page 36
1100
Length
(inches)
106
21
51
40
165
21
110
40
224
21
110
40
283
21
169
40
342
21
169
40
401
21
228
40
460
21
228
40
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Ratings — multiple SlimFit Series 3 boilers
(continued)
&IGURE Engineering data (see Figure 106 for notes)
Boiler
Model
Shipping
weight
Pounds
per boiler
Operating
weight
Pounds
per boiler
Water
content
Water flow rate
per boiler
Gallons
per boiler
GPM
@ 30°F rise
GPM
@ 40°F rise
Vent/air pipe
size —
Provide a
separate vent
for each boiler
Electrical
service
required
Note 3
Note 4
Note 2
Amps
per boiler
SF-550
505
476
5.5
34
26
6” or 8”
25 (boiler)
15 (Boiler
Circulator)
SF-750
550
529
6.5
47
35
6” or 8”
25 (boiler)
15 (Boiler
Circulator)
&IGURE Notes for Figure 104 and Figure 105
1
Foundation sizes in Figure 104 provide 12 inches between boilers and approximately 2 inches from boiler to edge of foundation.
Smaller foundations are possible with reduced service clearances.
See page 7 for details.
s For side-to-side installations, see Advanced Control Manual.
s For back-to-back installations, see Advanced Control Manual.
2
Operating weight is the total weight of the boiler, including water.
3
All SlimFit installations require a separate vent pipe and termination for each boiler. 6ENT PIPING CANNOT BE MANIFOLDED. Install and
terminate vents as described in vent/air installation instructions in this manual.
Combustion air piping can be individually piped or manifolded. See Figure 26, page 36, for manifolded air piping.
4
Boiler total amp load is 18 amps, which includes up to three circulators not exceeding 2.2 amps per circulator. Electrical service
required is the minimum recommended breaker or fuse size. DO NOT use larger than a 30-amp breaker or fuse.
In addition, circulator #4 requires a separate power supply for circulator amperage not to exceed 10 amps. Electrical service required
is the recommended breaker size of 15 amps. DO NOT use a higher-amp-rated breaker or fuse.
Installation and Service Certificate
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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)
Part number 550-100-168/0516
(Address)
(Phone)
(Installer’s Signature)
123
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Installation and Gas Boiler Data Collection Sheet
Boiler Model / Series SlimFit ________ / Series _______
Date Installed: ___________________
CP Number: __________________
BTU Input: ____________
Fuel Type: Natural___ LP___
Was venturi changed? YES___ NO___
Was gas valve throttle adjusted? YES___ NO___
Was gas valve offset adjusted? YES___ NO___
Boiler Settings
Network Settings
Priority 1 Settings
Boiler Model: SlimFit __________
Boiler Address: ____
System Type:
___________
Control Type: _________
Net Max On Time: _____Min
Target Mod Sensor:
___________
High Altitude: YES___ NO___
Net Min On Time: _____Min
Target Adjust:
___________
Max Rate On Net: _____%
Supply Max:
Min Rate On Net: _____%
Supply Min:
! "
Rotation & Sequence
OD Reset Max:
#$"
Sequence Type: ______
OD Reset Min:
'( Base Rate High: _____%
Volts For Max:
___________ V
Circulator Exercising
Base Rate Low: _____%
Volts For Min:
___________ V
Circulator 1: ON___ OFF___
Boiler Rotation Type: _________
Boost Time:
___________ Mins
Circulator 2: ON___ OFF___
Rotate Frequency: ____Days
System Off Diff:
Circulator 3: ON___ OFF___
Force Lead Rotation: YES or NO
System On Diff:
Boiler Circ:
Modbus Settings
Add BLR Diff:
Freeze Protection
Enable: YES___ NO___
Drop BLR Diff:
Circulator 1: ON___ OFF___
Address: __________
Mod Delay Time:
___________ Mins
Circulator 2: ON___ OFF___
Parity Bit: __________
Stabilization Time:
___________ Mins
Circulator 3: ON___ OFF___
Baud Rate: _________bps
Add Delay Time:
___________Sec
Boiler Circ:
Stop Bit: YES___ NO___
Drop Delay Time:
___________Sec
Assign Inputs
Max BLR Temp:
Input 1: Priority___ Aux___ OFF___
Boiler On Diff:
Source: TT1 ___ OR 0-10V ___
Boiler Off Diff:
Input 2: Priority___ Aux___ OFF___
Max On Time:
___________ Mins
Input 3: Priority___ Aux___ OFF___
Run Boiler Pump:
YES___ NO___
Run Aux Pump/Output:
YES___ NO___
Max Rate Volts: __________V
Pre Pump:
___________Sec
Min Rate Volts: __________V
Post Pump:
___________Sec
Temp Dependent: YES___ NO___
Max Rate:
___________%
$"#
Min Rate:
___________%
Max System BTUs:
__________ MBUTs
Min Boilers On:
___________
Additional Heat Demand:
1st___ 2nd___ OFF__
Response Time:
___________ Mins
ODT
YES___ NO___
ON___ OFF___
ON___ OFF___
Activate Contact
below setpoint: 1st____ 2nd____
124
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Installation and Gas Boiler Data Collection Sheet
CO2 @: High Fire______% Low Fire______%
CO@: High Fire _____ ppm Low Fire _____ ppm
Natural Gas / LP input rate measured: HIGH ______ CFH / LOW________ CFH
Priority 2 Settings
Priority 4 Settings
(Multi BLR Sys Only)
Priority 3 Settings
System Type:
___________
System Type:
___________
System Type:
___________
Target Mod Sensor:
___________
Target Mod Sensor:
___________
Target Mod Sensor:
___________
Target Adjust:
___________
Target Adjust:
___________
Target Adjust:
___________
Supply Max:
Supply Max:
Supply Max:
Supply Min:
Supply Min:
Supply Min:
OD Reset Max:
OD Reset Max:
OD Reset Max:
OD Reset Min:
OD Reset Min:
OD Reset Min:
Volts For Max:
___________ V
Volts For Max:
___________ V
Volts For Max:
___________ V
Volts For Min:
___________ V
Volts For Min:
___________ V
Volts For Min:
___________ V
Boost Time:
___________ Mins
Boost Time:
___________ Mins
Boost Time:
___________Mins
System Off Diff:
System Off Diff:
System Off Diff:
System On Diff:
System On Diff:
System On Diff:
Add BLR Diff:
Add BLR Diff:
Add BLR Diff:
Drop BLR Diff:
Drop BLR Diff:
Drop BLR Diff:
Mod Delay Time:
___________ Mins
Mod Delay Time:
___________ Mins
Mod Delay Time:
___________Mins
Stabilization Time:
___________ Mins
Stabilization Time:
___________ Mins
Stabilization Time:
___________Mins
Add Delay Time:
___________Sec
Add Delay Time:
___________Sec
Add Delay Time:
___________Sec
Drop Delay Time:
__________Sec
Drop Delay Time:
___________Sec
Drop Delay Time:
___________Sec
Max BLR Temp:
Max BLR Temp:
Max BLR Temp:
Boiler On Diff:
Boiler On Diff:
Boiler On Diff:
Boiler Off Diff:
Boiler Off Diff:
Boiler Off Diff:
Max On Time:
__________ Mins
Max On Time:
___________ Mins
Min On Time:
___________ Mins
Min On Time:
__________ Mins
Run Boiler Pump:
YES___ NO___
Run Boiler Pump:
YES___ NO___
Run Boiler Pump:
YES___ NO___
Run Aux Pump/Output:
YES___ NO___
Run Aux Pump/Output:
YES___ NO___
Run Aux Pump/Output:
YES___ NO___
Pre Pump:
___________Sec
Pre Pump:
___________Sec
Pre Pump:
___________Sec
Post Pump:
___________Sec
Post Pump:
___________Sec
Max Rate:
___________%
Max Rate:
___________%
Post Pump:
Max Rate:
___________%
Min Rate:
___________%
Min Rate:
___________%
Min Rate:
___________%
Max System BTUs:
__________ MBUTs
Max System BTUs:
___________ MBUTs
Max System BTUs:
___________MBUTs
Min Boilers On:
___________
Min Boilers On:
___________
Min Boilers On:
___________
Additional Heat Demand:
1st___ 2nd__ OFF__
Additional Heat Demand:
1st___ 2nd__ OFF__
Additional Heat Demand:
1st___ 2nd__ OFF__
Response Time:
___________ Mins
Response Time:
___________ Mins
Response Time:
___________Mins
ODT
YES___ NO___
ODT
YES___ NO___
ODT
YES___ NO___
Part number 550-100-168/0516
125
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Notes
126
Part number 550-100-168/0516
®
SlimFit Series 3
COMMERCIAL CONDENSING GAS-FIRED WATER BOILER
— Boiler Manual
Notes
Part number 550-100-168/0516
127
®
SlimFit
3 COMMERCIAL
CONDENSING
GAS-FIRED WATER BOILER — Boiler Manual
GAS-FIREDSeries
WATER BOILER
— Boiler
Manual
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