Weil McLain Boiler 382 200 305 User Manual

GV BOILER  
Intermediate or Back Section Repair Kit  
Part Number 382-200-305  
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.  
Indicates presence of hazard which  
can cause severe personal injury,  
death or substantial property damage.  
Indicates presence of hazard which will  
or can cause minor personal injury or  
property damage.  
WARNING  
CAUTION  
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.  
WARNING  
Wait until boiler is cooled down before proceeding with replacement.  
Contents of Kit:  
2” square cut seals  
7. Remove section(s) to be changed.  
Silicone sealant  
Nuts and washers for draw rods  
Instructions  
Instructions for blower removal/replacement  
8. Remove silicone sealant from mating sections.  
9. Clean new section and mating sections of any oil  
and dirt or silicone sealant will not adhere properly.  
10. Clean square cut sealing surfaces on new and  
mating sections.  
1. Remove jacket top and front panels. Lay aside boiler  
insulation.  
2. Close isolation valves between boiler and system.  
Drain boiler.  
Do not use any cleaner containing  
CAUTION  
petroleum-based distillate (oil). Square  
3. Remove:  
cut seal failure will occur.  
All wiring connectors from control tray.  
Control tray (if applicable).  
External system gas and water piping from boiler.  
Thermostat wiring.  
11. Apply bead of silicone sealant around perimeter of  
intermediate or back section except on inside of  
waterway holes (see Figure 1).  
External vent piping.  
External combustion air piping, if used.  
Vent condensate drain hose.  
Silicone  
Sealant  
Do Not  
Apply  
Silicone  
Sealant  
Here  
Blower assembly and burner. See “Blower Assembly  
or Burner Replacement Instructions,part number  
550-141-608, packed with kit.  
High limit control bulb from well.  
Relief valve and external piping (back section only).  
External air vent piping.  
Remaining outside and interior jacket panels.  
Block temperature limit switch.  
Circulator(s).  
Do Not  
Apply  
Silicone  
Sealant  
Here  
4. Tilt block assembly onto back section to rest on 2  
short pieces of 2 x 4’s.  
Section block is heavy - care must be  
CAUTION  
taken in moving to avoid personal  
injury.  
Figure 1  
12. Insert new square cut seals.  
13. Align new section and lay it on top of existing section.  
Repeat steps 10-12 as necessary.  
5. DO NOT remove drain valve and all other remaining  
piping on front section.  
6. Remove base rail assembly and tie rods from block  
assembly.  
Part number 550-141-588/0501  
 

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