Weil-McLain 382-200-300 manual Gv Boiler, Replacement Instructions, Front Section Repair Kit

GV BOILER

Front Section Repair Kit

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

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

Replacement Instructions

The following terms are used in these instructions to bring attention to presence of hazards of various risk levels, or to important information concerning the life of the product.

WARNING

Indicates presence of hazard which can cause severe personal injury, death or substantial property damage.

CAUTION

Indicates presence of hazard which will or can cause minor personal injury or property damage.

WARNING

Failure to follow items below can cause severe personal injury, death or substantial property damage:

These instructions are for use by a qualified installer/service technician. Follow all instructions in proper order.

Shut off main gas valve and disconnect electricity to boiler.

Wait until boiler is cooled down before proceeding with replacement.

Contents of Kit:

Ignitor Replacement Kit

Studs, nuts, washers, adapters, flange gaskets pump/ return water tubing

Square cut seals, silicone sealant Instructions

Instructions for blower motor/replacement

1.Remove jacket top and front panels. Lay aside boiler insulation.

2.Close isolation valves between boiler and system. Drain boiler.

3.Remove:

All wiring connectors from control tray. Control tray (if applicable).

External system gas and water piping from boiler. Thermostat wiring.

External vent piping.

External combustion air piping, if used. Vent condensate drain hose.

Blower assembly and burner. See “Blower Assembly or Burner Replacement Instructions,” part number 550-141-608, packed with kit.

High limit control and well. External relief valve piping. External air vent piping (if used).

Remaining outside and interior jacket panels. Block temperature limit switch. Circulator(s).

4.Tilt block assembly onto back section to rest on 2 short pieces of 2 x 4’s.

CAUTION	Section block is heavy - care must be
	taken in moving to avoid personal
	injury.

5.Remove drain valve and all other remaining piping on front section.

6.Remove vent ell and clean silicone sealant from vent ell (Series 1 & 2 only).

7.Remove base rail assembly and tie rods from block assembly.

8.Remove front section from block and remove silicone sealant from mating intermediate section.

9.Clean new front section and mating intermediate section of any oil and dirt - silicone sealant will not adhere properly.

10.Clean square cut sealing surfaces on new and mating sections.

CAUTION	Do not use any cleaner containing
	petroleum-based distillate (oil). Square
	cut seal failure will occur.

11.Apply bead of silicone sealant around perimeter of intermediate section, NOT on inside of waterway holes (see Figure 1).

Silicone

Sealant

Do Not

Apply

Silicone

Sealant

Here

Do Not

Apply

Silicone

Sealant

Here

Figure 1

12.Insert new square cut seals.

13.Align front section and lay it on top of intermediate section.

Part number 550-141-589/0501