Weil-McLain 382-200-300 Leitfaden

Partnumber550-141-589/0501

Front Section Repair Kit

Part Number 382-200-300 for Series 1 & 2

Part Number 382-200-300 for Series 3 & 4

GV BOILERGV BOILER

GV BOILER

Replacement InstructionsReplacement Instructions

Replacement Instructions

Failure to followitems belowcancause severepersonalinjury,death orsubstantial propertydamage:

Theseinstructions arefor use bya qualified installer/servicetechnician.Followall instructions in proper order.

Shut off main gas valve and disconnect electricity to boiler.

Wait until boileriscooled downbeforeproceeding withreplacement.

WARNING Indicates presence of hazard which

can cause severe personal injury,

deathor substantial property damage.

WARNING

The following terms are used in these instructions to bring attention to presence of hazards of various risk levels, or to important

informationconcerning the lifeofthe product.

IgnitorReplacementKit

Studs,nuts, washers,adapters, flange gaskets pump/

returnwatertubing

Squarecut seals,silicone sealant

Instructions

Instructionsfor blower motor/replacement

Contents of Kit:

CAUTION Indicatespresence of hazard whichwill

or can cause minor personal injury or

propertydamage.

1. Remove jacket topand frontpanels. Lay asideboiler

insulation.

2. Close isolation valvesbetween boilerand system.

Drainboiler.

3. Remove:

All wiring connectors from control tray.

Controltray (if applicable).

Externalsystem gasand water piping fromboiler.

Thermostatwiring.

Externalvent piping.

Externalcombustion air piping,if used.

Vent condensate drainhose.

Blower assembly and burner.See “Blower Assembly

orBurner Replacement Instructions,”part number

550-141-608,packed with kit.

Highlimit control andwell.

Externalrelief valve piping.

Externalair ventpiping (if used).

Remainingoutside and interiorjacketpanels.

Blocktemperature limit switch.

Circulator(s).

4. Tilt block assembly onto back section to rest on 2

short pieces of 2 x 4’s.

5. Remove drain valveand all otherremainingpiping on

frontsection.

6. Remove vent elland cleansilicone sealantfrom vent

ell (Series 1 & 2 only).

CAUTION Donot use anycleaner containing

petroleum-baseddistillate(oil).Square

cut seal failure will occur.

11. Applybeadof siliconesealantaround perimeterof

intermediatesection, NOTon inside of waterway holes

(seeFigure 1).

Figure 1

Silicone

Sealant

12. Insert new square cut seals.

13. Alignfrontsection andlay it ontop of intermediate

section.

7. Remove base rail assembly and tie rods from block

assembly.

8. Remove front section from blockand remove

siliconesealantfrom mating intermediatesection.

9. Cleannew front sectionandmating intermediate

section of any oil and dirt - silicone sealant will not

adhereproperly.

10. Clean square cut sealing surfaces on new and

matingsections.

Do Not

Apply

Silicone

Sealant

Here

Do Not

Apply

Silicone

Sealant

Here

CAUTION Section block is heavy - care must be

takenin moving to avoid personal

injury.

Front Section Repair Kit Part Number 382-200-300 — Replacement Instructions

Partnumber550-141-589/0501

Weil-McLain

500 Blaine Street

Michigan City, IN 46360-2388

http://www.weil-mclain.com

Installation — assembly

14. Insert draw rods.Make sure all sections are aligned

whendrawingtogether,tightentie rodnutsevenly

(35+ 5 ft.lbs. torque).

15. Re-installbaserail assemblyto bottomof block

assembly.Use a level to assure rails are parallel.

16. Applysiliconesealant aroundvent ell andinstall,

securing with screw (Series 1 & 2 only) (check that

condensatedrain hoseis securelyfastened).

17. Installstudsfor blowerhousing mounting bracketand

blocktemperature limit switch.

18. Reconnectdrainvalve andpiping on frontsection. See

BoilerManual.

a. Do not solderwater tubinguntil Step 19and all

pipingcomponentsare doped andtightened,

alignmentis critical.

b. Whenre-soldering watertubing,wet elbowsto

preventpipe dope shrinkage.

19. Installcirculator, assuring properalignment of pump(s)

toall circulator(s)flanges.

20. Afterallpiping componentsareconnected, thensolder

watertubing.

21. Pressure test block assembly and water tubing for

leaksas described in Boiler Manual.Repair,if found.

22. Replaceblowerassembly and burner.See“Blower

Assemblyor Burner ReplacementInstructions,”

part number 550-141-608,packed with kit.

23. Tilt block assembly back onto base rails.

24. Re-install:

Blocktemperature limit switch.

Jacketleft and interiorpanels.

Externalrelief valve piping.

Externalair vent piping.

Highlimit control andwell.

Externalvent piping.

Externalcombustion air piping,if used.

Ventcondensate drain hose.

External systemgas and waterpiping to boiler.

Controltray (if applicable).

All wiring connectors to control tray.

Thermostatwiring.

25. Fillboileras described inBoiler Manual.

26. Turn on electric andgas toboiler.Check boiler

normalsequence of operationand follow checkout

procedureinBoiler Manual.

27. Check for flue gas leakage around new section

usingmirror.Leakswill cause fogon mirror.Repair

any leaks with silicone sealant and recheck.

28. Replaceinsulationand jacketright, back, frontand

toppanels.

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