Install Instructions

Part number 550-100-131/0715
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GAS-FIRED WATER BOILER — Boiler Manual
&IGUREMinimum flame signal values during operation
-ODEL -INIMUM
mAMESIGNAL
-ODEL -INIMUM
mAMESIGNAL
EVG220
132 EVG220 LP 100
EVG299/300 148 EVG299/300 LP 132
EVG399 124 EVG399 LP 100
&IGUREFlame signal shut down values — the control
will shut the boiler down if flame signal levels
drop below the values below
-ODEL 3HUTDOWN
mAMESIGNAL
-ODEL 3HUTDOWN
mAMESIGNAL
EVG220 116 EVG220 LP 80
EVG299/300 128 EVG299/300 LP 112
EVG399 104 EVG399 LP 80
Annual startup (continued)
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good condi-
tion 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. Check settings of external limit controls (if any) and adjust
if necessary. Adjust as needed to accommodate the system
design.
Inspect pressure switch, wiring and tube
1. Inspect pressure switch, ensuring wire connects are properly
connected and tube is secured to pressure port.
2. Inspect tube for any signs of damage or debri collected in
tube, replace if necessary.
3. After checking Control Settings (see above), disconnect tube
connection with condensate dish. Gently blow on tube until
pressure switch opens and control displays lockout error.
Clear lockout on control and confirm that lockout does not
re-appear. Reconnect tube connection with condensate dish,
making sure connection is secure.
Perform startup and checks
1. Start boiler and perform checks and tests specified in this
manual.
2. Verify cold fill pressure is correct and that operating pressure
does not go too high. Adjust water pressure and expansion
tank charge pressure as necessary.
3. Complete the check-out procedure on page 90.
Check low water cutoff service light
1. If the low water cutoff amber LED is on, the LWCO requires
service.
2. Follow the manufacturer’s instructions packed with the low
water cut-off (shipped as standard equipment with all Ever-
green boilers, in the kit box).
Check burner flame and flame signal
The boiler contains ceramic fiber materi-
als. Use care when handling these materials
per instructions on page 92 of this manual.
Failure to comply could result in severe personal injury.
1. Inspect flame through observation window using the pro-
cedure on page 88.
2. If flame is unsatisfactory at either high fire or low fire, check
combustion values. If combustion is properly adjusted, turn
off boiler and allow boiler to cool down. Then remove burner
and clean it thoroughly using a vacuum cleaner or compressed
air. Do not use compressed air to clean burner if performed
inside a building.
3. To access the burner, remove the burner access panel and
the cover plate top following the procedure beginning on
page 109.
4. If removing the cover plate top and /or the burner, the burner
gasket must be replaced. Follow all instructions on page 112
to reinstall all components.
5. Restart the boiler.
6. Inspect the flame at high and low fire. If flame is still not
acceptable, check combustion values, Figure 86, page 89. If
combustion can not be properly adjusted, obtain a replace-
ment burner from Weil-McLain.
7. Check flame signal at both high fire and low fire.
8. Navigate to Diagnostics/Inputs on the Control display
(see Figure 71, page 73 for navigation instructions and
Figure 77, page 78 for the complete Diagnostics menus).
9. The flame signal value must be at least equal to the values
listed in Figure 91.
10. If the flame signal drops below this level, the Control will
attempt to correct by increasing the boiler firing rate to
increase flame signal.
11. A low flame signal may indicate a fouled flame sense rod.
a. See “Inspect Flame Sense Rod,” page 95 to remove and
inspect the flame sense rod.
b. If required, clean the flame sense rod as instructed.
c. Check combustion values.
d. If cleaning the flame sense rod does not improve, flame
Sense wiring is in good condition, and ground continuity
is satisfactory, replace the flame sense rod.
12. If flame signal still remains low:
a. See “Remove, Inspect and Clean the Burner,” see
page 109 to remove and replace burner gasket.
b. Inspect the vent and air piping.
c. Then inspect the heat exchanger, following the procedures
given in this manual for removal and reinstallation of the
heat exchanger cover plate and other boiler components
(see page 109).
d. Clean the exchanger as described in this manual if nec-
essary.