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'llht:afJit. Series 2 THE 1. WATER BOILER - 'l/ttm0/t. WATER Boiler Manual BOILER - How Weii-McLain logo plate (standard) or Remote Display Module (optional) The Remote Display Module (RDM) is used when the optional AFM (item 28) is installed. The display shows boiler and system status and is used to adjust operating parameters. 2. ON/OFF switch 3. Control Pod cover fastener 4. Pressure/Temperature gauge IT WORKS ••• 19.
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'llltlta()lt. Series 2 WATER BOILER - Boiler Manual Please read before proceeding t11 1 J!1 ~1ij4;1 Follow the guidelines below to prevent severe personal injury, death or substantial property damage. Fuel Do not use crankcase drainings or any oil containing gasoline. See burner manual for proper fuel oil. Never burn garbage or paper in the boiler. Never leave combustible material around boiler.
'llht:afJit. Series 2 WATER BOILER - IAWARNJNG 1. 2. Boiler Manual Homeowner responsibilities- read and follow completely. Have the boiler and burner installed by a qualified installer. Have the boiler and burner serviced at least annually by a qualified service t echnician. Review and understand boiler st art-up and routine maint enance procedures with the service technician. Perform routine maintenance listed below. 3. 4. Operation Maintenance Beginning of heating season ttj.
'llltlta()lt. Series 2 WATER BOILER - Boiler Manual Boiler location checklist Before placing the boiler, verify: United States installations must comply with all applicable U. S. codes: 0 Canadian installations must comply with all applicable Canadian codes: 0 Consider use of space 0 Moving boiler to location 0 Clearances 0 Flooring and foundation 0 Combustion and ventilation air openings 0 Venting .. . . .. . . .. .. . . .. .. . . . . . . . . . . ..
'llht:afJit. Series 2 Boiler Manual WATER BOILER - Prepare boiler location Provide minimum clearances Figure 1 From combustible materials (see Figure 1) 1. Hot water pipes • All directions - Vz inch. (not shown in Figure 1) 2. Double-wall vent pipe 0 Minimum clearances to combustible surfaces and recommended minimum service clearances / / / / / / / /< /<-------------, : 1iop V1ew ~ / D w.. -_-- " I • All directions - 6 inches. - - - -- 3. Single-wall vent pipe. - .....L._ 1 : 211 . .
'llltlta()lt. Series 2 WATER BOILER - Boiler Manual Prepare boiler location (continued) Flooring and foundation Follow code requirements Flooring 1. Install on any level, properly-supported, and noncarpeted surface. Flooring may be combustible if boiler leveling legs are installed. 2. Ensure the flooring is capable of handling the boiler weight (see page 39 for weight and water volume). Follow state, provincial or local codes when sizing adequate combustion and ventilation air openings.
'llht:afJit. Series 2 WATER BOILER - Boiler Manual Prepare boiler location (continued) Place the boiler: Remove outer crate 1. Remove outer crate, leaving boiler on the crate base. 2. Remove the circulator and barometric damper cartons from the crate base. 3. U0-3 boilers only - Remove the two flue baffles fastened to the cr ate base behind the boiler. 4. Remove the two shipping channels by loosening and removing the four nuts. Save the shipping channels for leveling leg installation. 5.
'11/tm()d. Series 2 WATER BOILER - Boiler Manual Prepare boiler location (continued) Perform hydrostatic pressure test: See pages 2 and 3 for boiler feature locations. l. Install air vent in relief valve tapping. 2. 3. 4. 5. 6. Figure 4 Burner door hinge installation Hinge bracket and screws (factory-installed on left side) Plug supply and return tappings. Install the boiler drain valve shipped with boiler. Fill boiler. Vent all air. Pressure test boiler at l lf2 times working pressure.
'llht:afJit. Series 2 WATER BOILER - Boiler Manual Prepare boiler location (continued) Install the burner l. Secure the burner flange to the burner door using the three bolts provided. 2. Check for secure placement of insulation and sealing rope on the burner door. 3. Close the burner door and secure in place with the burner door screws and washers. 4. Follow the burner manual and boiler manual (pages 19 to 22) to wire the burner and connect fuel lines.
'llltlta()lt. Series 2 WATER BOILER - Boiler Manual Connect breeching (continued) Chimney venting (continued) NOTICE Connect breeching: IAWARNINGI Long horizontal breechings, excessive number of tees and elbows or other obstructions restricting combustion gas flow can result in possibility of condensation, flue gas leakage and carbon monoxide emissions, which can lead to severe personal injury or death. 1. Connect full-sized breeching when possible. See Table 2, page 12, and Figure 5, below. 2.
'llht:afJit. Series 2 WATER BOILER - Boiler Manual Connect water piping General piping information: ASME or Canadian requirements If installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. Install control in supply piping between boiler and isolation valve. Set control to a minimum of 20 op above set point of the boiler limit temperature sensor. Maximum allowable set point is 220 °F. Wire control as shown on wiring diagram (page 20 & 21).
'llltlta()lt. Series 2 WATER BOILER - Connect water piping DIAPHRAGM expansion tank (Figure 6) Make sure expansion tank size will handle boiler and system water volume and temperature. Tank must be located near boiler before inlet to circulator. See tank manufacturer's instructions for details.
'llht:afJit. Series 2 WATER BOILER - Boiler Manual Connect water piping (continued) Piping MULTIPLE ZONES - System temperature 140 oF or higher d. Separate relay is required for each circulator. l. Follow instructions on page 14 and 15 to install piping near boiler. 2. Zoning with circulators (Figure 8) 3. Zoning with zone valves (Figure 9) a. Install balancing valves to adjust flow to distribute heat to all zones. b. Separate transformer is required to power zone valves.
'llltlta()lt. Series 2 Boiler Manual WATER BOILER - Connect water piping (continued) Piping MULTIPLE ZONES - System temperature below 140 oF 1. If system water temperature requirements are less than 140 °F, such as radiant panels or converted gravity systems, use piping as shown in Figure 10 or 11 . 2. If system piping is plastic without an oxygen barrier, a heat exchanger must be used. 3. Follow instructions on page 14 and 15 to install near-boiler piping. 4. Zoning with circulators (Figure 10) 5.
'llht:afJit. Series 2 WATER BOILER - Boiler Manual Connect water piping Connect wiring (continued) Piping boiler in refrigeration systems (Figure 12) Install boiler so that chilled medium is piped in parallel with heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. Consult AHRI Installation and Piping Guides.
'11/tm()d. Series 2 WATER BOILER - Boiler Manual Connect wiring Remove the Control Pod cover to facilitate wire routing. (To remove, push the Control Pod cover to one side, and gently work the cover retainer hinge on the other side out of the jacket slot.) Figure 14 Burner harness routing 120-volt wiring Conduits Connect each conduit supplying line-voltage wiring to or from the boiler to a conduit opening in the upper portion of the jacket rear panel.
'llht:afJit. Series 2 Boiler Manual WATER BOILER - Connect wiring (continued) This wiring diagram is for standard boiler equipment. For wiring with optional AFM, see AFM instructions. NOTICE Figure 15 Boiler and burner wiring, standard equipment ADVANCED FEATURES MODULE • OR • THERMOSTAT (NOTE 7) r;::::========r·-·:·-·~ Wiring Diagram ALERT OUTPUT FROM LWCO OFF BOILER 2 --------------------. I' II I!OIL£R 2 !' BLOCKED VENT UTOFF S'MTCH ! (CANADA ONLY) 1 BOILER TEMPERATURE :~:~ I..
'llltlta()lt. Series 2 Boiler Manual WATER BOILER - Connect wiring (continued) ___,_ , ___, ___, ___, _, ___., ___,_ , ___, ___, ___, _, ___., ___,_ , ___, ___, ___, _, ___., ___,_ Beckett GeniSys Primary Control7505 I I FACTORY WIRED SUBBASE I ~! I BURNER PRIMARY CONTROl (Bottom) @ Jumper TR· Tw terminals. Connec.t thermostat to boiler high limit. BLACK Beckett Burner Wiring Rlello F5 Burner Wiring --.. -.. -"---"- . -.. -"---"- . -.. -.. -.. -"- . _"- . -.. -"---"- . -.. -.. -.. -"---"- . -.
'lllka0/1. Series 2 WATER BOILER - Boiler Manual Connect oil piping General oil piping requirements: Location and installation of oil tanks, oil piping and burners must follow: NFPA 31, Standard for the Installation ofOil-Burning Equipment. In Canada, CSA Bl39, Installation of Oil-Burning Equipment. Local codes and regulations. Information provided with burner and fuel pump.
'llltlta()lt. Series 2 WATER BOILER - Boiler Manual Startup procedure Tips for water systems: Follow information below to prevent severe personal injury, death or substantial property damage: Do not use gasoline crankcase drainings or any oil containing gasoline. See burner manual for proper fuel oil. Do not attempt to start burner when excess oil has accumulated, when unit is full of vapor or when combustion chamber is very hot.
'llht:afJit. Series 2 WATER BOILER - Boiler Manual Check-out procedure be operating and should go off when controls are tested. When controls are restored, burner should re-ignite. 0 1. Boiler and heat distribution units filled with water? 0 2. Automatic air vent, if used, opened one full turn? 0 9. Limit control set to system temperature requirements (max. 220 °F)? 0 3. Air purged from system? Piping checked for leaks? 0 10.
'llltlta()lt. Series 2 WATER BOILER - Boiler Manual Annual service and start-up lA WARNlNGI 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 Table 4 must be performed to assure maximum boiler efficiency and reliability. See the following pages for detailed instructions. Failure to service and maintain the boiler and system could result in equipment failure.
'llht:afJit. Series 2 WATER BOILER - Boiler Manual Annual service and start-up (continued) lA WARNlNGI 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.
'llltlta()lt. Series 2 WATER BOILER - Boiler Manual Annual service and start-up (continued) Check all piping for leaks Check expansion tank IAWARNINGI 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.
'llht:afJit. Series 2 WATER BOILER - Boiler Manual Annual service and start-up (continued) Check boiler relief valve 1. Inspect the relief valve and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufacturer's warning label. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read page 14 regarding relief valves before proceeding further.
'11/tm()d. Series 2 WATER BOILER - Boiler Manual Annual service and start-up (continued) Clean boiler flueways and check refractory linings Figure 17 Access to boiler flueways !A WARNING! Make sure all electrical connections to boiler are turned off and wait until boiler is warm, not hot, before cleaning. Failure to do so will result in severe personal injury, death or substantial property dam age. IAWARNINGI The boiler contains fiberglass and ceramic fiber materials.
'llht:afJit. Series 2 WATER BOILER - Boiler Manual Removing/replacing boiler jacket Removing the boiler jacket Figure 18 Jacket components and hardware IAWARNINGI Electrical shock hazard - The following procedure assumes the boiler has not been wired. If the boiler has been wired, you must disconnect all power to the boiler. Then label all wires before disconnecting them at the boiler terminal strip. Control Pod cover IAWARNINGI The boiler contains fiberglass and ceramic fiber materials.
'llltlta()lt. Series 2 WATER BOILER - Boiler Manual Removing/replacing boiler jacket (cont.) 9. Push the Control Pod cover to one side, and gently work the cover retainer hinge on the other side out of the jacket slot to remove the cover. 10. Remove the limit temperature sensor and PIT gauge capillary from the wells in top of the boiler back section. 11. Remove the jacket cross tie by loosening the two screws securing it to the side panels (Figure 19).
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'llht:afJit' Series 2 WATER BOILER - Boiler Manual Dimensions CD Supply connection - 1W' npt ® Return connection - ® ® Pressure/temperature gauge 1Y2" npt ® Burner with cover Electrical entrance knockouts ® Drain valve @ Relief valve, elbow and nipple ® Control Pod cover ® Flue connection - ~--- - - - - ALL DIMENSIONS IN INCHES - - - - 6" diameter U0-3 - 36.56" U0-4 - 40.56" U0-5 - 44.56" U0-3 - 25.00" U0-4 - 29.00" U0-5 - 33.00" ---~ -+ 11.56" TOP T 1 .. 11.03"1 17.
'llltlta()lt. Series 2 WATER BOILER - Boiler Manual Ratings ~® c us Boiler Model Number ~ ~ H ~UDI ........ CERTIFIEDTM c AHRI Burner Capacity DOE Heating Capacity CSA Input CSA Output Net AHRI Ratings Boiler Water Content Shipping Weight, Approx. DOE Seasonal Efficiency GPH#20il MBH MBH Btuh MBH Gallons Pounds AFUE o/o Notes 1, 6 Notes 2, 6 Note2 Notes3,6 Notes: Flue Conn. Size Draft Loss Through Boiler Inches w.c. Note4 NoteS U0·3 0.8 GPH 0.80 98 112 98 85 15.
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