Weil-McLain 382-200-300 Guide

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 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.
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.