™ CONDENSING GAS BOILER 220/299/300/399 Boiler Manual s )NSTALLATION s -AINTENANCE s 3TARTUP s 0ARTS This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
™ GAS-FIRED WATER BOILER — Boiler Manual The Evergreen Gas-fired water boilers 3TAINLESS STEEL lRETUBE HEAT EXCHANGER "URNER ACCESS COVER HEAT EXCHANGER COVER PLATE "LOWER The advanced blower design and air inlet silencer on EvergreenTM boilers result in very quiet operation.
™ GAS-FIRED WATER BOILER — Boiler Manual The Evergreen Gas-fired water boiler (continued) Low voltage Part number 550-100-131/0715 Line voltage –3–
™ GAS-FIRED WATER BOILER — Boiler Manual Contents The Evergreen Gas-fired water boilers . . . . . . . . . . . . 2 Please read before proceeding . . . . . . . . . . . . . . . . 5 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . 6 Prepare boiler location . . . . . . . . . . . . . . . . . . . . . 8 Wall-mounting the boiler. . . . . . . . . . . . . . . . . . . . 8 Boiler hydrostatic test . . . . . . . . . . . . . . . . . . . .
™ GAS-FIRED WATER BOILER — Boiler Manual Please read before proceeding (AZARD DElNITIONS The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Indicates presence of hazards that will cause severe personal injury, death or substantial property damage. Indicates presence of hazards that can cause severe personal injury, death or substantial property damage.
™ GAS-FIRED WATER BOILER — Boiler Manual Boiler location Installations must comply with: s s s s Local, state, provincial, and national codes, laws, regulations and ordinances. National Fuel Gas Code, ANSI Z223.1/NFPA 54. National Electrical Code. For Canada only: CAN/CSA B149.1, Natural Gas and Propane Installation Code, and any local codes. The Evergreen boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.
™ GAS-FIRED WATER BOILER — Boiler Manual Boiler location (continued) Provide clearances for service access — RECOMMENDED Provide clearances from combustible materials — REQUIRED 1. See Figure 1 for recommended service clearances. 2. If you do not provide minimum service clearances shown, it might not be possible to service the boiler without removing it from the space. 1. See Figure 2 for REQUIRED minimum clearances. ALL installation must provide at least these minimums. 2.
™ GAS-FIRED WATER BOILER — Boiler Manual Prepare boiler location Wall-mounting the boiler Flooring and foundation &IGURE Boiler shipping container &LOORING 1. The boiler is approved for installation on combustible flooring, but must never be installed on carpeting. Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage. &OUNDATION 1.
™ GAS-FIRED WATER BOILER — Boiler Manual Wall-mounting the boiler (continued) Wall-mounting requirements &IGURE Place boiler on wall-mount bracket The wall-mounting kit is NOT supplied with the boiler, and must be purchased separately. 2. Verify kit contents: a. Wall-mount bracket b. Lag screws, 3/8”hex head x 3” (2) 3. Verify mounting location: a. Wood stud wall: install bracket with lag screws included in kit, directly into the studs. b.
™ GAS-FIRED WATER BOILER Wall-mounting the boiler (continued) 8. If upper spacer board is used, install the lower spacer board as shown in Figure 5, page 9. 9. Once the wall-mount bracket is installed, measure 35” below the bottom edge of the bracket and strike a line or place a piece of masking tape with the top edge even with the 35” mark. This line will indicate if the boiler has been properly seated in the hanging bracket. 10. /BTAIN ASSISTANCE TO LIFT THE BOILER INTO POSITION.
™ GAS-FIRED WATER BOILER — Boiler Manual Boiler hydrostatic test (continued) &IGURE Install piping fittings for relief valve and pressure/temperature gauge –– $/ ./4 MOUNT RELIEF VALVE UNTIL !&4%2 HYDROSTATIC TESTING &IGURE Install piping components required for hydrostatic test (see legend below) (see legend below) 1 3 Piping to system Recommended but not included 2 Piping from system 12 Legend for Hydrostatic Testing 1 Boiler supply (outlet) connection, male 1½” NPT.
™ GAS-FIRED WATER BOILER Boiler hydrostatic test — Boiler Manual Gas conversions (continued) 7. When water begins to exit from the supply outlet, close the boiler drain valve (item 12). 8. OPEN isolation valve 11. Close this valve when water begins to run from the return isolation shutoff valve (item 11). 9. Continue filling by opening the boiler drain valve (item 12) until water flows from supply outlet isolation shut-off valve (item 10). Then CLOSE isolation valve 10. 10.
™ GAS-FIRED WATER BOILER Gas conversions — Boiler Manual (continued) Natural Gas to Liquefied Petroleum (Propane) conversion kits (continued) %6' ,0 P/N 383-900-065 NG to Propane Gas Conversion Kit contents: 511-050-220 1 562-150-292 !"#$ % & ' ( ) 3 562-248-765 ( ) *+, .
™ GAS-FIRED WATER BOILER Gas conversions — Boiler Manual (continued) ,%'%.$ for Figures 11, 12, 13 and 14 Air Silencer Air silencer clips (2) Venturi Blower Gas valve Gas pipe Swivel nut Garlock Washer 7. Loosen swivel nut (Figure 11, item 7) on venturi-gas valve connection (item 6). See Figure 12. Gently set gas valve a side. &IGURE Removal of Natural gas venturi 3. If the jacket front door was not already removed, remove it. 4. Locate the blower and venturi (see Figure 11). 5.
™ GAS-FIRED WATER BOILER Gas conversions (continued) swivel nut. Replace silencer gasket and re-attach air silencer to venturi. See Figure 14, page 14. Inspect the gas pipe fitting connections on the gas valve and new venturi (Item 3, Figure 14, page 14) check the seal of the connections. Failure to comply will cause a gas leak, resulting in severe personal injury or death. Do not check for gas leaks with an open flame — use bubble test.
™ GAS-FIRED WATER BOILER — Boiler Manual Gas piping — sizing gas lines Boiler gas connection is ¾” NPT. Size gas lines large enough to provide gas to all connected appliances. Natural Gas: 0IPE SIZING FOR NATURAL GAS 1. Size gas piping from meter outlet to entrance of boiler in accordance with Figure 17 and Figure 18. 2. Use total input of all connected appliances. Divide total input in Btuh by 1,000 to obtain cubic feet per hour of natural gas. a.
™ GAS-FIRED WATER BOILER — Boiler Manual Venting/air piping — general 9OU MUST PIPE COMBUSTION AIR TO THE BOILER AIR INTAKE. Do not install the EvergreenTM boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage. Install air inlet piping for the Evergreen boiler as described in this manual.
™ GAS-FIRED WATER BOILER — Boiler Manual Venting & air — general &IGURE (continued) Evergreen™ venting and air piping — DIRECT VENT ONLY — OPTIONS and PIPING LIMITS The table below lists the acceptable vent/air pipe terminations described in this manual. Follow all instructions provided to install the vent/air system. ./4 3(/7. below, but also approved, are the polypropylene piping and terminations listed in Figure 21, page 19.
™ GAS-FIRED WATER BOILER — Boiler Manual Venting & air — general (continued) &IGURE Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet local codes (see Figure 108, page 115 for part/kit numbers) )TEM -ATERIAL 0LASTIC PIPING MATERIALS 5NITED 3TATES #ANADA (Note 2) 6ENT OR AIR PIPING 6ENT PIPING PVC schedule 40 (Note 1) ANSI/ASTM D1785 ULC S636 PVC-DWV schedule 40 (Note 1) ANSI/ASTM D2665 N/A CPVC schedule 40 (Note 1) ANSI/ASTM F441 ULC
™ GAS-FIRED WATER BOILER — Boiler Manual Commonwealth of Massachusetts installations Commonwealth of Massachusetts — 8IFO UIF CPJMFS JT JOTUBMMFE XJUIJO UIF $PNNPOXFBMUI PG .
™ GAS-FIRED WATER BOILER — Boiler Manual Vent termination requirements &IGURE The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance from adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/ CSA B149.1. The vent termination clearances below are for U.S.A.
™ GAS-FIRED WATER BOILER — Boiler Manual Boiler room air openings &IGURE Combustion and ventilation air openings for Evergreen™ Direct Vent installations. Provisions for combustion and ventilation air to be n accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Sidewall with separate pipes !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS &IGURE ).34!,,!4)/. 3%15%.#% — Separate pipes sidewall Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapters if specified. 1. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 20, page 18.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Sidewall with separate pipes (continued) See notices on previous page. &IGURE Multiple separate pipes sidewall terminations — maintain vertical spacing between vent and air fittings shown in Figure 24, page 23. All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death or substantial property damage. 2. Place wall penetrations to obtain minimum clearances shown in Figure 25 for U. S.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Sidewall with W-M vent/air plate !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapters if specified. 1. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 20, page 18.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Sidewall with W-M vent/air plate (continued) )NSTALL 7EIL -C,AIN VENT AIR CAP &IGURE Adjacent terminations — OUTSIDE VIEW — clearance from air inlet to exhaust from another appliance !$!04%23 — Use adapters if using other than 4-inch PVC or CPVC. This is required for different materials (polypropylene or AL29-4C stainless steel) or if using 3-inch pipe.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Sidewall concentric )NSTRUCTIONS BELOW are for the WM 3” and 4” PVC Concentric Kit. If using Simpson-Duravent or Centrotherm Concentric kit, please refer to the manufacturer’s installation instructions. &IGURE ).34!,,!4)/. 3%15%.#% — Concentric horizontal !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 21, page 19.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Sidewall concentric See notices on previous page. (continued) &IGURE Termination location — concentric termination — multiple boilers — clearance from vent of one to air intake of the next )NSTALL TERMINATION CONCENTRIC PIPES 1. Assemble the vent termination as described for concentric terminations, on page 33. If necessary, you can shorten the lengths of the inner and outer pipes for a shorter finished assembly.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Vertical with separate pipes !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS &IGURE Separate pipes vertical termination Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapters if specified. 1. Locate the terminations such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 20, page 18.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Vertical with separate pipes (continued) See notices on previous page. &IGURE Terminations for multiple boilers 0REPARE ROOF PENETRATIONS 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole at least 0.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Vertical concentric !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS &IGURE ).34!,,!4)/. 3%15%.#% — Concentric vertical 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapters if specified. 2.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Vertical concentric (continued) See notices on previous page. &IGURE Vertical termination — concentric termination — single or multiple boilers 2. Place roof penetrations to obtain minimum of 12 inches between centers of adjacent vent pipe of another boiler for U. S. installations (see Figure 37). 3. The air inlet of a EvergreenTM boiler is part of a direct vent connection.
™ GAS-FIRED WATER BOILER — Boiler Manual Concentric termination, typical &IGURE 06# concentric termination assembly — DO NOT attach the rain cap until the termination has been inserted through the roof or wall and all supports have been installed. See LEGEND at right. See kit instructions for details of polypropylene kits. (sidewall or vertical) ,%'%.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Vertical vent / sidewall air !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapters if specified. &IGURE ).34!,,!4)/. 3%15%.#% — Vertical vent/ sidewall air 1. Locate the terminations such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 20, page 18.
™ GAS-FIRED WATER BOILER — Boiler Manual DIRECT VENT — Vertical vent / sidewall air (continued) $ETERMINE LOCATION FOR AIR INLET ELBOW 1. The air inlet of an Evergreen boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent appliance terminations. 2. Locate the air inlet elbow (termination) using the following guidelines. 3. The air piping must terminate in a down-turned elbow as shown in Figure 42. a.
™ GAS-FIRED WATER BOILER — Boiler Manual Vent and air piping and boiler connections Follow termination instructions &IGURE Boiler vent and air connections Read and follow all instructions for the termination type used before proceeding with this page. Follow all instructions provided by vent pipe manufacturer. Use only materials from the manufacturers listed in Figure 21, page 19.
™ GAS-FIRED WATER BOILER — Boiler Manual Install water piping Use two wrenches when tightening water piping at boiler, using one of the wrenches to prevent the boiler interior piping from turning. Failure to support the boiler piping connections to prevent them from turning could cause damage to boiler components. See Replacement parts section at the end of this manual for the Weil-McLain low water cut-off kit. 4. Purchase low water cutoff and install in a tee in the supply piping above boiler. 5.
™ GAS-FIRED WATER BOILER Install water piping — Boiler Manual (continued) The following simplified method for pipe and circulator sizing must be limited to residential applications using baseboard (finned or cast iron), cast iron radiators or convectors. DO NOT apply for radiant heating, fan coil units or commercial installations. System water piping methods All piping methods shown in this manual use primary/secondary connection to the boiler loop.
™ GAS-FIRED WATER BOILER Install water piping — Boiler Manual (continued) &IGURE Flow rates for 0.04 feet head loss per foot of pipe (140°F water) Pipe size (inches) MAX Flow rate (GPM) Pipe size @ 0.04 feet per foot (inches) MAX Flow rate (GPM) @ 0.04 feet per foot ¾ 3.9 1 7.
™ GAS-FIRED WATER BOILER — Boiler Manual Expansion tank Expansion tank Figure 47 and Figure 48 show typical installations of the system expansion tank. Always locate the air separator and expansion tank as shown in the suggested piping drawings, beginning on page 41. &IGURE Piping to diaphragm (or bladder) type expansion tank Ensure that the expansion tank size will handle boiler and system water volume and temperature. Allow 4.6 gallons for Evergreen 220, 7.0 gallons for Evergreen 299/300 and 6.
™ GAS-FIRED WATER BOILER — Boiler Manual System piping - Single Boiler Systems See Advanced Manual for Multiple Boiler Systems ZONE VALVE zoning – primary/secondary &IGURE Zone valve zoning —primary/secondary connection — a system circulator is required (Shown with optional DHW piping) See Figure 49. This configuration is for zone valve systems using a boiler loop connected as a secondary circuit off of a primary system loop. 1.
™ GAS-FIRED WATER BOILER — Boiler Manual System piping - Single Boiler Systems (continued) See Advanced Manual for Multiple Boiler Systems Circulator zoning – primary/secondary &IGURE Circulator zoning plus optional DHW piping (Shown with optional DHW piping) See Figure 50. 1. This configuration is for circulator-zoned systems using a boiler loop connected as a secondary circuit off of a primary system loop. Systems zoned with circulators must pipe the boiler loop as a secondary circuit as show.
™ GAS-FIRED WATER BOILER — Boiler Manual System piping - Single Boiler Systems (continued) See Advanced Manual for Multiple Boiler Systems Circulator zoning – Multiple temperature zones with primary/ &IGURE Circulator zoning with high- and low-temperature heating zones secondary (Shown with optional DHW piping) See Figure 51. 1.
™ GAS-FIRED WATER BOILER — Boiler Manual System piping - Single Boiler Systems (continued) See Advanced Manual for Multiple Boiler Systems Radiant Heating — Circulator zoning – &IGURE Typical radiant heating system piping — primary/secondary (Shown with optional DHW piping) circulator zoning See Figure 52. 1. The Evergreen boiler is ideal for use in radiant heating. The unique heat exchanger design allows it to work well even in condensing mode.
™ GAS-FIRED WATER BOILER — Boiler Manual System piping - Single Boiler Systems (continued) See Advanced Manual for Multiple Boiler Systems DHW as a zone — CIRCULATOR zoning primary/secondary &IGURE Circulator zoning with DHW as a zone See Figure 53. 1. Install a separate circulator for each zone. 2. Install the DHW tank as a system zone. The DHW tank can be piped as a zone ONLY if a DHW tank is ./4 connected to the boiler. 3. Wire the DHW circulator to boiler Priority 1.
™ GAS-FIRED WATER BOILER — Boiler Manual System piping - Single Boiler Systems (continued) See Advanced Manual for Multiple Boiler Systems WATER CHILLER systems — ZONE VALVES &IGURE Chilled water system plus optional DHW primary/secondary piping See Figure 54. 1. The chiller must be piped in parallel with the boiler. 2. Use appropriate valves to prevent chilled medium from entering boiler. 3.
™ GAS-FIRED WATER BOILER — Boiler Manual Install condensate line Prepare condensate fittings &IGURE Condensate trap assembly 1. Remove PVC fittings and gasket from the accessories bag. 2. Deburr and chamfer outside and inside of ½” PVC nipple to ensure even cement distribution when joining. 3. Clean nipple ends and all fittings. Dry thoroughly. 4. For each joint in the condensate line, apply the following. Assemble parts ONLY in the order given (See Figure 55). a.
™ GAS-FIRED WATER BOILER Install condensate line Condensate drain tubing — Boiler Manual (continued) &IGURE Condensate pump (by others), typical 1. Connect condensate drain tubing to the ½” PVC tee and run to floor drain or condensate pump (see Figure 59, page 48). Use ½” PVC or CPVC pipe; or 5/8” I. D. tubing (Installer supplied). Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785, F441 or D2665.
™ GAS-FIRED WATER BOILER — Boiler Manual Gas piping EvergreenTM boilers are shipped ready to fire &IGURE Connect gas supply piping natural gas ONLY. You must install the propane venturi if the boiler will be connected to propane. See page 12. Failure to comply could result in severe personal injury, death or substantial property damage. 'AS PIPE SIZING See page 16 for gas line sizing information. Connecting gas supply piping 1. Refer to Figure 60 to pipe gas to boiler. a.
™ GAS-FIRED WATER BOILER Field wiring — Boiler Manual (see wiring diagram, Figure 62, page 57) &IGURE Field wiring overview (see Figure 62, page 57 and Figure 63, page 58 for detailed schematic and ladder wiring diagrams) %,%#42)#!, 3(/#+ (!:!2$ — For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.
™ GAS-FIRED WATER BOILER Field wiring — Boiler Manual (see wiring diagram, Figure 62, page 57)(continued) A. 120 VAC Power Supply – REQUIRED 4ERMINAL "LOCK 4 (control tray, right front) 1. Provide and install a properly sized fused disconnect or service switch as required by applicable codes. (15-amp for most cases.) a. Use table at right to determine total load. Suggested fused disconnect or service switch sizing is 15-amp if total load is 12 amps or less, 20-amp if total load is more than 12 amps.
™ GAS-FIRED WATER BOILER Field wiring — Boiler Manual (see wiring diagram, Figure 62, page 57)(continued) # 6!# TO "OILER #IRCULATOR – REQUIRED 4ERMINAL 3TRIP 0 ON 0UMP #OMM "OARD (control tray, left side) 1. Provides 120VAC to the boiler circulator at Pump/Comm Board P8 Terminals. 2. Terminals are: 1 (H), 2 (N), 3 (G). 3. Maximum load: 2.2 amps (use relay if circulator load is higher). See WARNING above. 4.
™ GAS-FIRED WATER BOILER Field wiring — Boiler Manual (see wiring diagram, Figure 62, page 57)(continued) % 3YSTEM SUPPLY AND RETURN TEMPERATURE SENSORS – REQUIRED 4ERMINAL "LOCK 0 (EVG control module, left side) 1. Two strap-on temperature sensors are shipped with the boiler. Attach one to the system supply piping and the other to the system return piping. For piping larger than 5 inch diameter or nonmetallic piping, using immersion sensors will provide faster response. 2.
™ GAS-FIRED WATER BOILER Field wiring — Boiler Manual (see wiring diagram, Figure 62, page 57)(continued) 4O CAUSE AUTOMATIC RESET 4ERMINAL "LOCK 0 (EVG control module, left side) %6' CONTROL WILL RESET AUTOMATICALLY AFTER CIRCUIT IS INTERRUPTED 1. Remove factory-installed jumper and connect isolated contacts of external limits across P13 pins 3 and 4 to cause the control to shut down the boiler on limit opening, then automatically restart 150 seconds after the limit closes. 2.
™ GAS-FIRED WATER BOILER Field wiring — Boiler Manual (see wiring diagram, Figure 62, page 57)(continued) K. Proof of closure (flow switch and/or CAD) – see ADVANCED Manual – OPTIONAL *UMPER ON 4ERMINAL 3TRIP 0 (EVG control, bottom left of center) 1. A flow switch or combustion air damper (CAD) interlock can be configured by clipping the jumper on terminal strip P7 and wiring components as shown at right and in the wiring diagram (Figure 62, page 57). 2.
™ GAS-FIRED WATER BOILER Field wiring — Boiler Manual (see wiring diagram, Figure 62, page 57)(continued) M. 0–10 VDC Remote MODULATION input – OPTIONAL 4ERMINAL "LOCK 0 (EVG control module, left side) 1. See illustration at right and Figure 62, page 57 for details. 2. This illustration also shows how to connect TT or end switch contacts at INPUT 2 and INPUT 3 for other uses. 3. Note that using 0–10VDC input disables INPUT 1 as shown at right. 4.
™ GAS-FIRED WATER BOILER — Boiler Manual Wiring diagram — schematic &IGURE Evergreen schematic wiring diagram (see Figure 63, page 58 for legend and notes) Part number 550-100-131/0715 – 57 –
™ GAS-FIRED WATER BOILER — Boiler Manual Wiring diagram — ladder &IGURE Evergreen ladder wiring diagram (see Figure 62, page 57 for schematic wiring diagram) – 58 – Part number 550-100-131/0715
™ GAS-FIRED WATER BOILER — Boiler Manual Zoning with the EVG Control A. Zoning with CIRCULATORS, suggested applications 4HREE SPACE HEATING ZONES NO $(7 1. Review wiring information on page 51 (120VAC outputs) and page 52 (24VAC inputs). 2. The configuration at right uses the three input/output pairs to receive thermostat inputs on P11-4/5, P15-1/2, and P15-3/4; and circulator outputs on P2 as shown. 3. The factory default settings assign all inputs 1, 2 and 3 to PRIORITY 2. 4.
™ GAS-FIRED WATER BOILER — Boiler Manual Zoning with the EVG Control (continued) B. Zoning with ZONE VALVES, suggested applications 4WO SPACE HEATING ZONES NO $(7 1. Review wiring information on page 51 (120VAC outputs) and page 52 (24VAC inputs). 2. The configuration at right uses INPUT 2 and 3 for space heating thermostats. INPUT 1 is reserved here for configuring the operation of the system circulator. 3. The factory default settings assign inputs 1, 2 and 3 to PRIORITY 2.
™ GAS-FIRED WATER BOILER — Boiler Manual Evergreen Control operation Evergreen control setup 1. Set control parameters using the WIZARD option provided on initial start-up or manually enter parameters using control menus (see Figure 71, page 73 and following pages for information.) 2. See %XPRESS SETUP instructions beginning on page 66 for basic systems and minimum settings required (using factory defaults). 3.
™ GAS-FIRED WATER BOILER — Boiler Manual Evergreen Control operation EVG control Priorities & Input/Outputs s s s s s s s For heating installations with multiple systems, the EVG control uses PRIORITIES to determine the order of operation of the systems. The control’s MAX and MIN time settings determine the maximum and minimum times a system will be operated before being turned off to allow another system to operate.
™ GAS-FIRED WATER BOILER — Boiler Manual Evergreen Control operation Outdoor reset operation (continued) &IGURE Outdoor reset operation 1. Set desired temperatures for space heating zones. 2. For an explanation of the target temperatures and associated outdoor temperatures, see Figure 65. 3. The temperature settings discussed below are accessed in the priority menu for the applicable system. For detailed explanations of the priority menus, see Figure 73, page 75. 3500,9 -!8 1.
™ GAS-FIRED WATER BOILER — Boiler Manual Evergreen Control operation (continued) &IGURE Evergreen single boiler essential settings (2%15)2%$ on initial start-up) — see page 72 for explanation – 64 – Part number 550-100-131/0715
™ GAS-FIRED WATER BOILER — Boiler Manual Evergreen Control operation (continued) &IGURE Evergreen control display screens and typical navigation Part number 550-100-131/0715 – 65 –
™ GAS-FIRED WATER BOILER — Boiler Manual EXPRESS SETUP — EXAMPLE A -ULTI ZONE SPACE HEATING #IRCULATORS WITH CIRCULATOR RELAYS \ DHW (Direct-piped) "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe EVG CONTROL SETTINGS (IN ORDER OF WIZARD SEQUENCES) personal injury, death or substantial property damage. Incorrect setup or piping can result in severe personal injury, death or substantial property damage.
™ GAS-FIRED WATER BOILER — Boiler Manual EXPRESS SETUP — EXAMPLE A (continued) -ULTI ZONE SPACE HEATING #IRCULATORS WITH CIRCULATOR RELAYS \ DHW (Direct-piped) Evergreen boiler. Indirect water heater, if used (domestic water piping not shown) — MUST be direct piped to boiler to use default control settings. Relief valve, supplied with boiler, field piped — MUST be piped to boiler supply connection — see Figure 6, page 11 for information. Unions as needed for service.
™ GAS-FIRED WATER BOILER — Boiler Manual EXPRESS SETUP — EXAMPLE B OR :ONE SPACE HEATING #IRCULATORS WITHOUT CIRCULATOR RELAYS \ DHW (Direct-piped) "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe EVG CONTROL SETTINGS (IN ORDER OF WIZARD SEQUENCES) personal injury, death or substantial property damage. Incorrect setup or piping can result in severe personal injury, death or substantial property damage.
™ GAS-FIRED WATER BOILER — Boiler Manual EXPRESS SETUP — EXAMPLE B (continued) OR :ONE SPACE HEATING #IRCULATORS WITHOUT CIRCULATOR RELAYS \ DHW (Direct-piped) Evergreen boiler. 2 Indirect water heater, if used (domestic water piping not shown) — MUST be direct piped to boiler to use default control settings. Relief valve, supplied with boiler, field piped — MUST be piped to boiler supply connection — see Figure 6, page 11 for information. Relief valve piping to drain.
™ GAS-FIRED WATER BOILER — Boiler Manual EXPRESS SETUP — EXAMPLE C -ULTI ZONE SPACE HEATING :ONE VALVES "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe 7-:6 CONTROLLER \ DHW (Direct-piped) EVG CONTROL SETTINGS (IN ORDER OF WIZARD SEQUENCES) personal injury, death or substantial property damage. Incorrect setup or piping can result in severe personal injury, death or substantial property damage.
™ GAS-FIRED WATER BOILER — Boiler Manual EXPRESS SETUP — EXAMPLE C -ULTI ZONE SPACE HEATING :ONE VALVES (continued) 7-:6 CONTROLLER \ DHW (Direct-piped) Evergreen boiler. Indirect water heater, if used (domestic water piping not shown) — MUST be direct piped to boiler to use default control settings. Relief valve, supplied with boiler, field piped — MUST be piped to boiler supply connection — see Figure 6, page 11 for information. Relief valve piping to drain. DHW circulator.
™ GAS-FIRED WATER BOILER — Boiler Manual Available control settings and system presets &IGURE Evergreen control settings available in BASIC MODE (see Advanced Manual for ADVANCED MODE settings) !VAILABLE SETTINGS FROM #/.42!#4/2 -%.
™ GAS-FIRED WATER BOILER — Boiler Manual CONTRACTOR menus "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITI CAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the UP and DOWN arrow keys at the same time for 7 seconds. 2. See the following pages for explanations of control setting options. &IGURE Evergreen control menu access — accessing contractor menus -ORE INFORMATION -%.
™ GAS-FIRED WATER BOILER — Boiler Manual BOILER SETTINGS menu, BASIC mode "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITI CAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the UP and DOWN arrow keys at the same time for 7 seconds. 2. See Figure 71, page 73 for the screen sequences up to the CONTRACTOR menu.
™ GAS-FIRED WATER BOILER — Boiler Manual PRIORITY 1, 2, 3 menus, BASIC mode "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITI CAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the UP and DOWN arrow keys at the same time for 7 seconds. 2. See Figure 71, page 73 for the screen sequences up to the CONTRACTOR menu.
™ GAS-FIRED WATER BOILER — Boiler Manual ASSIGN INPUTS menu, BASIC mode "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITI CAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the UP and DOWN arrow keys at the same time for 7 seconds. 2. See Figure 71, page 73 for the screen sequences up to the CONTRACTOR menu.
™ GAS-FIRED WATER BOILER — Boiler Manual ASSIGN INPUTS menu, BASIC mode (continued) &IGURE AUX PUMP/OUTPUT operation (accessed in ASSIGN INPUTS menu – see Figure 74, page 76) /PTION !CTIVATION CONDITIONS !,7!93 /. s %84%2.!, 37)4#( s s /54$//2 "%,/7 773$ s s s !.9 44 ).054 s s !.9 44 ).054 "9 )43 02)/2)49 3%44).'3 s s "52.%2 $%-!.$ s 3UGGESTED USES s Hot loop for seasonal boilers that are manually Output is always energized whenever the control is powered.
™ GAS-FIRED WATER BOILER — Boiler Manual DIAGNOSTIC menu &IGURE $)!'./34)#3 menu navigation (see Figure 68, page 65 for access information) -ENUS .EXT SCREEN .EXT SCREEN .EXT SCREEN .
™ GAS-FIRED WATER BOILER — Boiler Manual DIAGNOSTICS menu (continued) &IGURE $)!'./34)#3 menu navigation, continued (see Figure 68, page 65 for access information) -ENUS .EXT SCREEN .EXT SCREEN .EXT SCREEN .EXT SCREEN Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data DIAGNOSTICS (cont.) NETWORK INPUTS Shows input status of all network boiler inputs. (shows on master boilers only) SOFTWARE VERSIONS PAST ERRORS DISPLAY WM#.## MAIN MICRO WM#.
™ GAS-FIRED WATER BOILER — Boiler Manual DIAGNOSTICS menu (continued) &IGURE $)!'./34)#3 menu details (see Figure 68, page 65 for access information) -ENU )TEM #OMMENT 4EMPERATURES "OILER /UT Current operating status of the boiler.
™ GAS-FIRED WATER BOILER — Boiler Manual DIAGNOSTICS menu (continued) &IGURE $)!'./34)#3 menu details (continued) (see Figure 68, page 65 for access information) -ENU )TEM #OMMENT 2UN 4IMES "URNER 4IME 2OTATE 4IME )NPUT 4IME )NPUT 4IME )NPUT 4IME .ETWORK 4IME )GNITION #OUNT Displays cumulative time the burner has been active (can be increased by user) Records the days of operation passed from the last time the Master boiler rotated the firing sequence.
™ GAS-FIRED WATER BOILER — Boiler Manual DIAGNOSTICS menu (continued) &IGURE $)!'./34)#3 menu details (continued) (see Figure 68, page 65 for access information) -ENU )TEM 4IME $ATE 3TATUS 4EMPERATURES )NPUTS /UTPUTS ,OCKOUT (ISTORY &AULT .AME &AULT 4YPE 4IME $ATE 3TATUS 4EMPERATURES )NPUTS /UTPUTS ,OCKOUT (ISTORY &AULT .
™ GAS-FIRED WATER BOILER — Boiler Manual MAINTENANCE, DATE AND TIME menus &IGURE -!).4%.!.#% $!4% !.
™ GAS-FIRED WATER BOILER — Boiler Manual Startup — fill the system &IGURE Tools needed for start-up 4OOL 0URPOSE #2 Phillips screwdriver Multiple uses Flat blade screwdriver To assemble the condensate trap Multimeter Measurements on sensors and electrical components Manometer (Inclined or digital) Measure the INLET gas pressure to the boiler Combustion analyzer (Digital preferred) Combustion testing and boiler adjustments Contact thermometer Checking surface temperatures of heat exchanger
™ GAS-FIRED WATER BOILER — Boiler Manual Startup — fill the system (continued) Freeze protection (if used) Follow these guidelines to prevent possibility of severe personal injury, death or substantial property damage: 5SE ONLY THE PRODUCTS LISTED BY 7EIL -C,AIN FOR USE WITH THIS BOILER 3EE PAGE FOR INFORMATION 4HOROUGHLY mUSH ANY SYSTEM THAT HAS USED GLYCOL before installing the new EvergreenTM boiler. 2EVIEW THE MATERIAL SAFETY DATA SHEETS -3$3 are available online.
™ GAS-FIRED WATER BOILER — Boiler Manual Startup — final checks &ILL CONDENSATE TRAP WITH WATER Check for gas leaks Before starting the boiler, and during initial operation, use a leak detector or smell near the floor and around the boiler for gas odorant or any unusual odor. Remove boiler front door and smell the interior of the boiler jacket. $O NOT PROCEED WITH STARTUP IF THERE IS ANY INDICATION OF A GAS LEAK 2EPAIR ANY LEAK AT ONCE. $/ .
™ GAS-FIRED WATER BOILER — Boiler Manual Startup — final checks (continued) &IGURE Operating instructions (WARNING — Verify that the Control is set for the correct boiler model before proceeding.
™ GAS-FIRED WATER BOILER — Boiler Manual Startup — final checks (continued) ❏ #HECK SYSTEM AND BOILER 1. Check system piping for leaks. If found, shut down boiler and repair immediately. (See WARNING on page 84 regarding failure to repair leaks.) 2. Vent any remaining air from system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.
™ GAS-FIRED WATER BOILER — Boiler Manual Startup — final checks (continued) &IGURE Acceptable combustion values — Gas Valve Adjustment measured values must be within the ranges given below $/ ./4 attempt to adjust the throttle or offset screw unless done by a qualified technician, and with the use of calibrated combustion test instruments. Adjust the throttle or offset screw only as needed to meet the combustion values given in Figure 86.
™ GAS-FIRED WATER BOILER — Boiler Manual Startup — final checks (continued) ❏ #HECK (EAT EXCHANGER AND VENT SEALS 1. Operate the boiler on HIGH fire. 2. Using an inspection mirror, move the mirror around all heat exchanger joints and vent pipe connections at the top of the boiler and at the connection to the condensate dish. 3. A leak would appear as vapor on the surface of the mirror. 4. If there is any indication of a leak at any joint, immediately shut down the boiler. a.
™ GAS-FIRED WATER BOILER — Boiler Manual Annual startup and general maintenance 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.
™ GAS-FIRED WATER BOILER — Boiler Manual Annual startup FIRST-YEAR SPECIAL INSPECTION ANNUAL STARTUP 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 Figure 87, page 91 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability.
™ GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Address reported problems DO NOT SERVICE THE BOILER WITHOUT AN EvergreenTM Inspect any problems reported by owner and correct before proceeding. INSPECTION KIT AVAILABLE Inspect boiler area be required if inspection of components indicates the 1. Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids. 2.
™ GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) s Check all piping for leaks Eliminate all system or boiler leaks. Continual fresh make-up water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage. 1. Inspect all water and gas piping and verify to be leak free. 2.
™ GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) 3. Remove the air baffle (item 2) and screws (item 4) from the jacket top as shown. Remove and inspect ignition electrode assembly and wiring 1. See Figure 90, page 96 (EVG 220 shown) for component references below. 2. Disconnect the ground wire and ignition cable connected to the ignition electrode assembly (item 7). 3.
™ GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) ,%'%.$ &IGURE 0!243 ! AND " ! " Boiler interior assembled view (Model EVG 220 shown; component locations vary with other models) Boiler interior exploded view, showing heat exchanger cover plate (item 6) blower, burner assembly, burner access cover seal (item 13), ignitor, flame sense rod, and sight glass.
™ GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Check all boiler wiring 1. Inspect all boiler wiring, making sure wires are in good condition and securely attached. 2. Verify that all connectors are securely inserted. 3. Verify ground wires are connected to jacket right side and control tray cover. Check control settings 1. Use the Control display to navigate through all settings. Adjust settings if necessary. 2.
™ GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Check blower speeds 1. For installations at altitudes above 2,000 feet, make sure the control is set up for correct altitude in the boiler setup menu. The Control automatically adjusts low fire and ignition rates to compensate for high altitude conditions. &IGURE Firing rates and corresponding blower speeds (low fire, ignition, and high fire) — for altitudes up to 5,500 feet and high altitude (above 5,500 feet). -ODEL Fuel % Type 2.
™ GAS-FIRED WATER BOILER — Boiler Manual Annual startup (continued) Manual Test Mode for Single and Multiple Boilers Single Boiler 1. Navigate to Manual Test Mode screen under DIAGNOSTICS menu. 2. Generate a call for heat and wait until the burner is lit, if not yet in operation. 3. Press ENTER and select the desired FORCE RATE. Rate will be forced to setting for 10 minutes. Multiple Boiler Running 1. Generate a call for heat on a Network Priority or a Local Priority a.
™ GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting Before calling for troubleshooting assistance, fill in the “%VERGREEN4- 'AS $ATA #OLLECTION 3HEET” (page 130). Record the boiler size and CP number (located on the outside left jacket above the rating label). &AILURE TO ADHERE TO THESE GUIDELINES CAN RESULT IN SEVERE PERSONAL INJURY DEATH OR SUBSTANTIAL PROPERTY DAMAGE ELECTRICAL SHOCK HAZARD The boiler ON/OFF switch does not turn off all power to the boiler. 452.
™ GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) 5. If necessary, replace one or all of the fuses: Check Control fuses ALWAYS check control fuses before replacing control or any major components (blower, etc.). If one of these fuses is blown, it can prevent control or other components from operating. 1. Turn OFF power to boiler at external line switch. Then remove the jacket door. 2. Remove four (4) screws holding control tray cover in place. 3.
™ GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) -AKE SURE TO DETERMINE THE CAUSES OF OUTAGES $O NOT LEAVE THE BOILER OPERATING WITHOUT A COM PLETE DIAGNOSIS Control fault indications 1. The control provides diagnostic information for both automatic reset conditions and manual reset conditions. See Figure 68, page 65 for information available on the control display and navigation instructions for all menus. &IGURE – 102 – 2.
™ GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) RESET TO FACTORY DEFAULT 1. Selecting this will prompt the user to hold the enter button for a specified length of time. Upon completion, this will reset the control settings back to factory installed settings. ONCE THIS IS CHOSEN, PREVIOUS SETTINGS CANNOT BE RECOVERED. ENSURE THIS ACTION IS TRULY DESIRED BEFORE CONTINUING. &IGURE 2. Reset to Factory Default can be found on the BOILER SETTINGS menu, see Figure 72, page 74.
™ GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) &IGURE Troubleshooting suggestions for EvergreenTM boilers — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Display Condition Nothing shown $POUSPM JT OPU SFDFJWJOH 7 on display QPXFS screen and boiler will not respond to call for heat Nothing is $POUSPM JT OPU SFDFJWJOH 7 shown in display QPXFS screen and no other boiler components are operating Nothing is shown on display screen, but boiler is operating 0DDVST JG U
™ GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) &IGURE Troubleshooting suggestions for EvergreenTM boilers — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Display LOW WTR CUTOFF OPEN Condition 0DDVST JG JOUFSOBM MPX XBUFS DVUPõ DPOUBDUT PQFO Diagnostics "VUPNBUJD SFTFU PDDVST JG contacts are open at least one TFDPOE CVU MFTT UIBO TFDPOET Manual reset of control if contacts are open longer than 5 seconds.
™ GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) &IGURE Troubleshooting suggestions for EvergreenTM boilers — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Display LIMIT OPEN Condition Diagnostics 0DDVST JG NBOVBM PS BVUPNBUJD "VUPNBUJD FYUFSOBM MJNJU XJMM reset l imit op ens. reset 2½ minutes after external limit device closes. .BOVBM MJNJU GBVMU NVTU CF SFTFU CZ DIPPTJOH .BOVBM 3FTFU PO the display.
™ GAS-FIRED WATER BOILER — Boiler Manual Troubleshooting (continued) &IGURE Troubleshooting suggestions for EvergreenTM boilers — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Display IGNITION FAULT Condition Diagnostics Corrective Action(s) #PJMFS XFOU UISPVHI JHOJUJPO "VUPNBUJDBMMZ SFTFUT BGUFS IPVS $IFDL DPOEFOTBUF USBQ GPS CMPDLBHF BMMPXJOH DPOEFOTBUF UP BDDVNVMBUF attempts and never detected PS DBO CF SFTFU CZ QFSGPSNJOH inside heat exchanger.
™ GAS-FIRED WATER BOILER — Boiler Manual Maintenance DO NOT SERVICE THE BOILER The EvergreenTM maintenance kit includes essential compo- WITHOUT AN EvergreenTM nents that must be replaced when accessing or disassembling MAINTENANCE KIT AVAILABLE parts of the boiler. Failure to replace damaged components and to use only the parts specifically intended for the boiler can result in severe personal injury, death or substantial property damage. See Figure 108, page 115 for part number.
™ GAS-FIRED WATER BOILER — Boiler Manual Cleaning heat exchanger flue side The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 92 of this manual. Failure to comply could result in severe personal injury. &IGURE Remove the burner access panel and screws (1 and 3) and air baffle and screws (2 and 4) from the jacket top as shown Tools required 1. Allen wrench, 3 mm (T-wrench preferred). 2. 8 mm socket with 8-inch extension. 3.
™ GAS-FIRED WATER BOILER — Boiler Manual Cleaning heat exchanger flue side Inspect combustion chamber and refractory 1. Look into the burner opening in the heat exchanger cover plate. 2. Use a trouble light and inspection mirror to inspect the heat exchanger interior. a. Make sure that there is no debris inside the heat exchanger. b. Use the inspection mirror to check the condition of the burner refractory that is adhered to the bottom of the heat exchanger cover plate.
™ GAS-FIRED WATER BOILER — Boiler Manual Cleaning heat exchanger flue side 5. If the vacuum cleaner is unable to clean completely, wash the heating surfaces with clean, warm water,using the following procedure. a. Place a shallow pan under the boiler condensate drain connection. b. Loosen the condensate trap clamp (item 22) and slide the drain line off of the drain connection. (See Figure 106, page 113 for reference.) c. Spray water into the heat exchanger and tubes to remove sediment.
™ GAS-FIRED WATER BOILER — Boiler Manual Cleaning heat exchanger flue side (continued) Reinstall components 1. See Figure 106, page 113 for reference. 2. Obtain the new burner gasket (item 12) from the Maintenance Kit and install into the heat exchanger cover plate. 3. Reinstall the burner gasket (item 12), burner (item 11), and burner access cover seal (item 13) on the heat exchanger cover plate (item 6). a.
™ GAS-FIRED WATER BOILER — Boiler Manual Cleaning heat exchanger flue side (continued) &IGURE Accessing the burner or heat exchanger (see Legend on page 112), (Evergreen 220 shown).
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts DO NOT SERVICE THE BOILER WITHOUT A EvergreenTM MAINTENANCE &AILURE TO ADHERE TO THESE GUIDELINES CAN RESULT IN SEVERE PERSONAL INJURY DEATH OR SUBSTANTIAL PROPERTY DAMAGE KIT AVAILABLE The EvergreenTM maintenance kit includes compo- OBTAIN PARTS ONLY THROUGH WEIL-McLAIN nents that may have to be replaced when accessing or disassembling parts of the boiler.
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Miscellaneous parts and kits 0ART .UMBER Description Description Antifreeze, Sentinel X500 (1 gal) . . . . . . . 592-900-029 Antifreeze, Sentinel X500 (5 gal) . . . . . . . 592-900-006 Sidewall separate pipes vent/air termination kits (includes two cover plates) Corrosion inhibitor, Sentinel X100 . . . . . . . 592-900-002 Kit for 3” or 4” PVC vent and air pipes . . . . . Sentinel X100 Quick Test Kit . . . . . .
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Jacket parts — EvergreenTM 220/299/300/399 (see Figure 110, page 117 for illustration) Item Name Description / contents Part Number 100 Front door (Includes W-M badge and door gaskets) 383-900-073 110 Front door gasket kit Seals for front door to jacket (Includes right, left and top gaskets) 383-900-070 120 Wall-mount bracket (jacket side) (Includes screws) 383-900-086 130 Door latch (2 required) ,QFOXGHV
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Jacket assembly — EvergreenTM 220/299/300/399 (see Figure 109, page 116 for part numbers) *DVNHW VKRZQ LV SURYLGHG LQ Item 130, pages 119 and 121 Gasket Kit P/N 383-900-028 'O TO WWW WEIL MCLAIN COM TO LOCATE 7EIL -C,AIN DISTRIBUTORS Part number 550-100-131/0715 – 117 –
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Heat exchanger parts EvergreenTM 220 (see Figure 112, page 119 for illustration) Item Name Description / contents Part Number 100 Heat exchanger, gaskets and hardware (Includes items 130 and 150) 383-900-025 110 +HDW H[FKDQJHU FRQGHQVDWH GLVK FRYHU SODWH EXUQHU LJQLWHU VLJKW JODVV UHIUDFWRU\ ZDWHU VHQVRUV JDVNHWV silicone, and hardware (Includes items 120 through 280) 383-900-069 120 Condensate dish
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE EvergreenTM 220 heat exchanger assembly (see Figure 111, page 118 for part numbers) 'O TO WWW WEIL MCLAIN COM TO LOCATE 7EIL -C,AIN DISTRIBUTORS Part number 550-100-131/0715 – 119 –
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Item Heat exchanger parts EvergreenTM 299/300/399 (see Figure 114, page 121 for illustration) Name Description / contents Heat exchanger, gaskets and hardware (Includes items 130, and 150) 0ART .UMBER Model 299/300 383-900-024 100 383-900-023 (Includes items 120 through 280) 120 Condensate dish, gaskets, and hardware (Includes item 130) 130 Gasket to seal heat exchanger to condensate dish 150 5HIUDFWRU\ LQ
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE EvergreenTM 299/300/399 heat exchanger assembly (see Figure 113, page 120 for part numbers) Part number 550-100-131/0715 – 121 –
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Piping components for EvergreenTM 220/299/300/399 (see Figure 116, page 123 for illustration) Item Name 0ART .
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Piping components for EvergreenTM 220/299/300/399 (see Figure 115, page 122 for part numbers) 'O TO WWW WEIL MCLAIN COM TO LOCATE 7EIL -C,AIN DISTRIBUTORS Part number 550-100-131/0715 – 123 –
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Controls & electrical components — EvergreenTM 220/299/300/399 (see Figure 118, page 125 for illustration) Item Name 0ART .UMBER Description / contents 100 Flue temperature sensor One sensor 511-724-292 110 Outdoor temperature sensor One sensor 510-312-218 120 6\VWHP WHPSHUDWXUH VHQVRU (2 required) 383-500-601 130 Low water cutoff Low water cutoff 511-100-005 140 7UDQVIRUPHU Y Y 50-60 Hertz transf
™ GAS-FIRED WATER BOILER — Boiler Manual Replacement parts (continued) &IGURE Controls & electrical assemblies — EvergreenTM 220/299/300/399 (see Figure 117, page 124 for part numbers) 'O TO WWW WEIL MCLAIN COM TO LOCATE 7EIL -C,AIN DISTRIBUTORS Part number 550-100-131/0715 – 125 –
™ GAS-FIRED WATER BOILER — Boiler Manual Dimensions &IGURE Dimensional data — EvergreenTM 220/299/300/399 (all dimensions in inches) 4/0 ,%&4 2)'(4 &2/.4 Boiler supply tapping — 1½” NPT. Boiler return tapping — 1½” NPT. Control panel, with display and navigation buttons. Electrical entrance openings. Vent connection: 4” PVC. – 126 – Gas connection – ¾” NPT (manual gas valve shipped loose for field installation) See page 49 for details and instructions.
™ GAS-FIRED WATER BOILER — Boiler Manual Ratings &IGURE Ratings and engineering data — EvergreenTM 220/299/300/399 DOE AHRI Certified Ratings % Input derate vs vent length Boiler Model Input Heating Capacity Seasonal Efficiency Net Water Rating Btuh MBH AFUE, % MBH (Note 5) (Note 2) (Note 1) %6' 220,000 206 %6' 299,000 280 (Values shown are at MAX vent/air pipe length — See Note 6) $IRECT 6ENT 6ENTING /.
™ GAS-FIRED WATER BOILER — Boiler Manual Ratings — Multiple boilers &IGURE Ratings and engineering data — multiple EvergreenTM boilers "OILERS IN SYSTEM %6' %6' %6' 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 "OILER -ODEL 3HIPPING WEIGHT Pounds per boiler 4OTAL #3! INPUT #3! /UTPUT $/% (EATING CAPACITY "OILER ( 0 .ET WATER RATINGS -ANIFOLDED COMBUSTION AIR DUCT SIZE Input, MBH Output, MBH - MBH Square inches - Note 1 - Note 2 440 412 12.
™ GAS-FIRED WATER BOILER — Boiler Manual Installation and Service Certificate "OILER $ATA "OILER -ODEL 3ERIES Evergreen ???????? 3ERIES ???? $ATE INSTALLED ????????????????????? #0 .UMBER ???????????????? "TU )NPUT &5%, .ATURAL ?????? ,0 ?????? ❏ ❏ ❏ ❏ #%24)&)%$ 4(!4: ??????????????????? Installation instructions have been followed. Check-out sequence has been performed. Information on next two pages is certified to be correct. Information received and left with owner/maintenance person.
™ GAS-FIRED WATER BOILER — Boiler Manual Installation and Gas Boiler Data Collection Sheet A ! % B MMMMMMMM % MMMMMMM ; . L MMMMMMMMMMMMMMMMMMM & H E L MMMMMMMMMMMMMMMMMM A R . L MMMMMMMMMMMM O Q L H MMM MMM O > Q .
™ GAS-FIRED WATER BOILER — Boiler Manual Installation and Gas Boiler Data Collection Sheet &< ]L >) O MMMMMMX O MMMMMMX &<]L >) O MMMMM O MMMMM H % L .
™ 132 GAS-FIRED WATER BOILER — Boiler Manual
