Weil-McLain GV BOILER 382-200-305 Guide

Partnumber550-141-588/0501
Intermediate or Back Section Repair Kit
Part Number 382-200-305
GV BOILERGV BOILER
GV BOILERGV BOILER
GV BOILER
Replacement InstructionsReplacement Instructions
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.
2” square cut seals
Siliconesealant
Nuts and washers for draw rods
Instructions
Instructionsfor blower removal/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 bulbfrom well.
Reliefvalve andexternal piping (back section only).
Externalair vent piping.
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. DO NOT remove drain valve and all other remaining
pipingon front section.
6. Remove base rail assembly and tie rods from block
assembly.
CAUTION Donot use anycleaner containing
petroleum-baseddistillate(oil).Square
cut seal failure will occur.
11. Applybeadof siliconesealantaround perimeterof
intermediateor backsection except on inside of
waterwayholes (see Figure 1).
Figure 1
12. Insert new square cut seals.
13. Alignnew section and lay it on top of existing section.
Repeat steps 10-12 as necessary.
7. Remove section(s) to be changed.
8. Remove silicone sealantfrom matingsections.
9. Clean new section and mating sections of any oil
anddirt or silicone sealant willnot adhere properly.
10. Clean square cut sealing surfaces on new and
matingsections.
CAUTION Section block is heavy - care must be
takenin moving to avoid personal
injury.
Silicone
Sealant
Do Not
Apply
Silicone
Sealant
Here
Do Not
Apply
Silicone
Sealant
Here

Intermediate or Back Section Part Number 382-200-305 — Replacement Instructions
Partnumber550-141-588/0501
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. Installcirculator(s),assuring properalignment of
pump(s)to both circulatorflanges.See BoilerManual.
17. Pressure test block assembly and water tubing for
leaksas described in Boiler Manual.Repair,if found.
18. Replaceblowerassembly and burner.See“Blower
AssemblyorBurnerReplacement Instructions,”part
number550-141-608, packed withkit.
19. Tilt block assembly back onto base rails.
20. Re-install:
Blocktemperature limit switch.
Jacketleft and interiorpanels.
Reliefvalve and piping.
Externalair vent piping.
Highlimit control bulbto well.
Externalvent piping.
Externalcombustion air piping,if used.
Vent condensate drainhose.
Externalsystem gasand waterpiping to boiler.
Controltray (if applicable).
All wiring connectors to control tray
Thermostatwiring.
21. Fillboileras described inBoiler Manual.
22. Turn onelectric andgas to boiler.Checkboilernormal
sequenceof operation andfollow checkout procedure
inBoilerManual.
23. Check for flue gas leakage around new section using
mirror.Leaks will cause fog on mirror.Repair any leaks
withsilicone sealantand recheck.
24. Replaceinsulationand jacketright, back, frontand top
panels.