v
Installation
Start-up
Boiler Parts
v
Boiler for Gas,Light Oil and Gas/LightOil Fired Burners
v
P a r t N o . 5 5 0 -l 4 l - 7 0 5 / 0 4 9 3 D C P
Read This Page First
U
Hazard Definitions
hazards
The following defined terms are used throughout this manual to bring attention to the presence of
product.
the
life
of
the
of various risk levels, or to important information concerning
Indicates presence of hazard which will cause severe personal injury, death
or substantial property damage if ignored.
Indicates presence of hazard which can cause severe personal injury. death
or substantial property damage il'ignored'
Indicates presence of hazard which will or can cause minor personal injury
or property damage if ignored.
Indicates special instructions on installation, operation, or maintenance
which are important but not related to personal injury hazards'
When Calling or Writing about the Boiler
please have model and series fiom boiler rating label ancl CP number(s) fronr boilcr jackct or controls.
Read all instructions before installing.
Failure t.o follow all instructions in proper order can cause
severe personal injury, death or substantial property clanrage'
Do not use petroleum-based cleaning or sealing compounds in boiler system.
Severe damage to system components can result, causing substantial property damage.
Table of Contents
v
Section A: Before Installing Boiler....
..'.4 - 5
Section B: Set Packaged Boiler or Block Assembly in Place 6
Section C: Assemble Block
Section D: Perform Hydrostatic Pressure Test
.......7 - 12
.......'.13
Section E: Connect Water Piping
....'. 14 - 15
Section F: Connect Steam Piping
......16 - 19
Section G: Install Jacket
Section H: Pipe Tankless Heaters
.........2O
.............2O
Section I: Install Water Boiler Controls
...........21
Section J: Install Steam Boiler Controls
....22 - 23
Section K: Connect Breechinfl and Venting Systems .......'24
SectionL: Install Burner
S e c t i o t ' tM : W i r i n g a n d F - u e lP i p i n g
SectionN: Make Final Adiustnlents ...
....---....25
. . ' . . . . 2 6- 2 7
Section O: Data and Dimensions
.'...28 - 29
Section P: Parts
. . . . . 3 O- 3 l
Ratings
b
.'........25
..Back Cover
Section A: Before InstallingBoiler
Installations must comPlY with:
o State. pro','incial and local plumbing,
electrical codes.
o Regulations of senring utilities.
o National codes where applicable.
heating and
Before selecting boiler location:
o Check for nearby connections to:
fuel sr-rpply
electrical power
system water or steam PiPing
- r,'entinA systems - see page 24.
combustion and ventilation air supply - see "Providc
combustion and ventilation air supply openings"
below.
o Check area around boiler for and remove any combustible materials, gasoline and other flammable vapors
ancl liouids.
Failure to keep boilcr area clear and
free of combustible materials, Aasoline and other flammable liquids and
vapors can rcsult in severc personal
injury, death and substantial property damagc.
Provide combustion and ventilation air openings:
Do not install arn exhaust lan in boiler
room. Adequatc combustion and ventilation air must be provided to assure propcr
combustion and prevent possibility of flue
gas lezrkage and carbon monoxide emissions, causing severe personal injury or
death.
GRATING_
M I N ,I 2 ' A B O V E
AVG,SNOWLINE
Opening sizes must comply with state, provincial or local
codes. In their absence. use the following when boiler is in
a confined room:
o Provide two penniar-rent openings in boiler room - one
within 12 inches of ceiling. one ','v'ithin l2 inches of
floor. Minimum dimension of each opening - 3 inches.
When all air is taken from rvithin building, each
opening should be at least one square inch/
1'ooo Btuh boiler input and freell' connect with
areas having adequate infiitration from outside.
When all air is taken from outdoors. each opening
should connect directly or by ducts with outdoors
or crawl or attic spaces that lreely connect with
outdoors ancl sized as listed below:
through outside wall or vertical ducts - at least
one square inch/4,000 Btuh boiler input.
through horizontal ducts - a least one square
inch/2,000 Btuh boiler inPut.
where ducts are used, they should be same
cross-sectional area as lree area of openings
they are connect.ed to.
Compcnsate lbr louver, grille or screcn blockage whcn calculating liee air openings. Refer to
thcir mzrnufacturer's instntctions lbr size . If
ttnkrtowlr, ttse:
wood louvcrs - 2o-25oh free air.
metal louvers or grilles - 60-750/o lree air.
screens - not less than l/4 inch mesh.
l,ock louvers in open position, or interlockwith
equipment to prove open belbre boiler opera-
o
tion.
L O U V E R M I N ,I 2 "
ABOVEAVG.SNOWLINE
SIZEOF AREAWAY
TO
AND GRATING
B EE Q U A LT O O R
THAN
GREATER
TOTALTOUVER
AREA.
NOTE:DUCTSIZE
TO
EQUAT
TOTAL
AREA
LOUVER
AREAWAY
ROOI'1
BOILER
FTOOR
Combustion and Ventilation Air Openings
Boiler Room Below Grade
Figure I
4
Combustion and Ventilation Air Openings
Boiler Room Partially or Completely Above Grade
Figure 2
t/
Section A: Before lnstalling Boiler
U
Provide clearances for servicing around boiler:
o Back, for breeching - 30 inches
o lrft side, for cleaning and tankless heater removal
- 34 inches
o Allow sufficient space on remaining sides for cleaning.
servicing and burner installation. Seebumer lilerattlre
for length.
o Clearancefronr vent pipe to conlbuslible rnaterials:
- singlewallvent pipc - l8 inches
- clouble.'vallvent pipe - rel'erto vent pipe t-llatlul-rctltrlbr vent pipe cle:rrances
cr's re('ontlllendatiot'ts
coNT'D
Lay a foundation, if needed:
Floor constmction and condition must be suitable for
weight of boiler when filled with water' See back cover page
for boiler/water weight.
A level concrete or brick foundation is required when:
o Floor couid possibly become flooded;
o Non-levelconclitionsexist.
L E N G T HT A B L E
FOUNDATION
BOILER
BOILER
MODEL
"1"
lNCHES
BOILER
MODEL
"1"
INCHES
378
23
878
58
478
30
9't8
65
578
37
| 078
f2
578
44
I t78
79
178
5l
t278
85
2"
MIN.
*
v
Boiler Foundation
Figure 3
Section B: Set PackagedBoiler or Block Assembly in Place
For packaged boiler:
1. Removetop jacket panel. Set aside until after boiler
is piped.
2 . Remove lag screws (2 in front, 2 in rear) from shipping
5.
6.
7.
rails.
Remove boilerfrom skid. Cables are already attached to
block assembly. See Lifting Weight Chart.
.
Using crane - hook middle of each cable to eye of
crane.
o
Using hoist - hook middle of each cable to hoist.
Raise boiler olf skid. Use pipe rollers unc'ler skicl
angles to roll boiler.
Place boiler in final oosition. Center boiler on founda
tion. if used.
kvel boiler. Shirn under skid angles, il.necessary
Cut off czrbles.
Cables are not intendecl for long-term
usage. Cables may corrode inside boil
er. weakening their lifting strength.
Failure to remove cables can result in
severe personal injury, death or
substantial properff damage.
Proceed to "Section D: Perforrn Hvdrostatic Pressure
Test," page 13.
For block assembly:
l.
Remove lag screws (2 in fiont, 2 in rear) Irom shipping
r:rils.
2. Remove boiler liom skicl. Cables are already atl.ached to
block zrssembly. See Lifting Weight Chart.
o
attach free end ofcables to eye of
Using crane
orane.
o
Using hoist - attach free end of cables to hoist.
Raise boiler off skid. Use pipc rollers under steel
skid angles to roll boiler.
3.
4.
5.
tl.
Place boiler in final position. Center boiler on foundation. if used.
Level boiler. Shim under skid angles. il.necessary.
Cut off cables.
Cables :rre not intended for lon$-term
usage. Cables nrat'c-orrode inside boilcr. .,veakeninq their lifting strength.
Failure 1o renlove t'erbles can result in
severe personal injtln'. de:rth or sub
s t a n l i i r l l ) r o l ) e n vd r t t t t a t e .
Inspecl block assembly lbr clisjointcd scctions. Check
gas-t.ight seal of llue collector hood. llue collar and
cleanout plates.
Gas t.ight seal nrttst l;e nt:rintained trr
prevent possiblc lluc g:rs leakage and
carbon monoxicle enrissirtns, resulting in severe persor-ralin-jury or death.
a. Open damper in flue collar.
b. Check insidc section assembly for any light passing
through unsealecl areas.
c. Mark:rll unsealcd areas.
d. At unsr::rlecl arc:rs, check lor darnaged gaskets,
sealing rope not in place, loosc bolts or nuts. or
missin{ holclclorur t'lips. Correct all conditions ancl
rcl)(':lt step l). ll trrtst'irlt'rl:ireas still t:xist. contact
vour \Vcil-Mt'l;rirt clistrilttttor or s:rles ofTit't:belirre
continuing installatiol-t.
I)roct:t'cl to "Secrtion D: I)erlirnn Hvclrostatic I)ressure
Test," pngc 13.
0
L I F T I N GW E I G H TC H A R T
BOILER
MODEL
PACKAGED ASSEMBLED
BLOCK
BOILER
LBS.
LBS.
BOILER
MODEL
PACKAGED A S S E M B L E D
BLOCK
BOILER
LBS.
LBS.
378
|355
It50
878
26s0
2325
418
r6r5
| 385
978
29t0
2560
578
|875
| 620
I0 7 8
3r65
2795
678
2t30
| 855
It78
t425
3030
778
2390
2090
1278
3680
3265
T
6
Section C: Assemble Block
Sections are top heary. Unbolted
iniury or death.
sections may fall if not supported, resulting in severe personal
Place I /2" sealing rope in groove.Around curves, grasp
a1 l" intenals and push together. Do not stretch.
Install back refractory blanket:
Lay back section on floor with ports lace up.
l.
2
Apply water glass as an adhesive to blerr.rket.
3. Press blanket against back target wall :rs shotrr in
Fi{ure 4.
1. Using knife. cut hole through blanket to exposc obser
vation poft opening.
3.
Prepare back section:
l. Apply 1/S" continuous bead o1'sealing rope adhesive in
scaling rope grooves. See Figure 4. Do not get any
adhesive on machined port surlaces.
4.
SEALING
ROPE
cur oFF
R O P EE V E N/
WITI-1EDGE
E@
:"il$ffi"::1fi:"r,:?:'.9"1l,
Itr@
""#;:'::]#fi:1,
:':ili:n
3."
J:iJ;
sibility of flue gas leakage and carbon
rnonoxide emissions, causing severe
personal injury or death.
Remove anv grit liorn pofl mzrchined surlaces with
clean rag.
tem. Severe darnage Lo system components can result, causing substzrnlial
propcrly damage.
Place 7- I /2" and 3-l /2" scaling rings in appropriate
port openings. See Figure 4. If sealing ring slips out ol
groove, stretch ring gently for scverarl seconds, then
reposition in groove.
<--
7: SEAL1NCRING
,,,,->
S E A L I N GR O P E
I
\
!
CUT OFF
ROPEEVEN
WITH
EDGE
BACKREFRACTORY
WATERGTASS
1APPLY
BACK
TO ENTIRE
srDE)
Figure 4
Section C: Assemble Block
5.
coNT'D
Draw sections together until metal-to-metal contact is
made around machined port openings (see Figure 6):
a. Oil threacls on 4 drarv rods. Install washer and nut
on end to bc tightencd. Use nut only on other end.
b. Unilbrrnlv clra.,vscctions together. starting atwasherlnut end.
c
Draw rods shoulcl bc torqtrccl to a range of 9O to lOO
ft.-lbs. Do not back ofT clr:ru' rocls.
Metal-to-nrctal t'ontact u'ill bc acl-rieveclaround
porl openings. See Fier-rre6. Il'Qap does exisl, it
should be no gre:rtcr th:rrr .032 . Check wit.h feeler
gauge.
('. If for any re:lson. g:tp arottnd n'r:rchined porl
opening exceecls .032". r'l-reck lbr ropc extencling
liom rope groo\rcs. clirt on por.1openings or sockets,
or misalignecl lrrgs. Il'c'on'ections zrrc ntade :rnd g:rp
still exists, conl:r('t r'ourWeil Mcl,ain clistributor or
sillersolfice belbre continuino installzrtion.
All.er erectin{ flrst intermediate section. chcck bottr sections lbr plumb.
Failure to piumb sections can cause
rnisaligned piping ancl brecching,
resrrlting in rninor property damage.
Repeat stcps I Il lionr "l)reparc l;:lck section."
Apply continuous bead of silicone sealant no larger
than l/16' around entire outside edge ofouter
machined surface of port. Refer to Figure 5. Do not
apply silicone sealant on, next to or under sealing
ring.
Silicone sealant applied as specified
above prevents unburned oil vapors
liom coming in contact with sealing
ring. Vapor contact can damage rings.
resulting in severe dam:r.ge to boiler
and substantial propefly clamage.
."'^'=,,
-".
,ffi,l
",;4.i4
i:
SILICONE
SEALANT
APPLIED
PERSTEP#5
Figure 5
7
Position section upright on lbundation (if used) and
screw 3" pipe at least 22" long into 3" return tapping
Place a block under pipe to hold section upright.
--l
L
2.
E@
3.
I
"
*:11if
;T:1""
;'#Hi,?T#3S"ffi
"Y
severepersonal injury or death.
Remove and discard 3/8" diameter shipping tie rocls.
Remove grit lrom porl machined surfaccs with clean
rag.
I
Figure 6
Instafl bottom refractory blanket on combustion
chamber floor inside section block:
l.
Unroll blanket only to depth of back section and first
intermediate section.
2. Spread water glass on bottom side of blanket.
3. Press blanket into center bottom of sections.
4. Unroll and install blanket per steps 2 and 3 as e:rc'h
intermediate and front section are installed.
5. At front section, cut olf blanket 2-1/2' front brtnrer
opening. Discard unused blanket.
""3ffi:':H:ifi"i,:i"$j*
3.'J:ffi
tem. Severedamage to system components can result, causing substantial
propeny damage.
Position intermediate section so aligning lugs fit into
sockets of nexl section. Refer to Figure 6.
I
)
/l
,L
Prepare intermediate section:
E@
SEAL
NG
R1NG
Section C: Assemble Block
Prepare remaining sections:
1. Follow "Prepare interrnediate section" for remaining
intermediate and front sections:
a. Remove any grit from threads inside tapped holes
with ('lean rag.
l).
Do not use petroleum-based cle:rningor sealing compounds in boiler
system. Severe damage to system
components can result, causing
substantial property damage.
-ll
Install
ffankless Intermecliate) and SI (Supply
Intcrmcdiate) sections (when used) in order shown
in "Section Arrangement Table".
(llrcck t'irc'hsec'tion lbr proper sealing rope position
bt'lorc proceecling to next section.
Failure to position sealing rope:
properlv can ('ausc boiler to not
st-al qas tieht. Clirs lialrt scal
pr('\'('nts possilrk' l)rrc qlrs lcakaec
;ttlrI r ,rtlroI) It)oIl{)\i(lI r'ttti\\i(,tl\.
cl.
r c s u l t i t r q t n s t ' r ' t ' r t 'p t ' r s o r r i r l
injrrn' or rlcath.
Mal<r' srrrc bottonr rclr-acton-blankct has br.r'n
irrslalk'rlI)er instnrctions on p:rgc 8.
SECTION ARRANGEMENT TABLE
SECTION ARRANGEMENT
(all heaters must be on
left side of boiler)
coNT'D
lnstall burner mounting plate on front section:
L
Install four | / 2" x 1-3 / 4" studs to secure burner mounting plate to section:
a. Thread and lock together trvo nuts on rounded
end of stud. Thread llat end of stud into one of
four holes located around opening.
b. Remove nuts.
c. Repeat steps a and b lbr remaining studs.
2. Install burner mounting plate:
a. Apply l/8' continuous bead of sealing rope adhesive in groove around opening in section.
b. Position l/2" sealing rope in groove. Overlap ends
at least one inch.
c. Install burner mounting plate. Use I /2" washers
and nuts.
Install observation
BOILER
MODEL
MAXIMUM
NO. OF
HEATERS
378W&S
I
F-TI -B
478 \^/&S
I
F-Tt - t-B
578 W&S
2
F-Tt-t-Tt-B
678W&S
2
F-Tt-t-Tt-t-B
778 \v&S
2
F-Tt-l-Tl-t-r-B
l.
878W&S
3
F-Tt-t-Tt-t-t-Tt-B
2
978 \^/&S
3
t 0 7 8w
3
t 0 7 8s
3
il78 \^/
4
il78 S
4
r278W
4
lf using Tl sections:
Install lankless hezrterszrndgaskets or heater co'"'erplates
a n c lg a s k e t s .U s e 3 / 8 " x 3 / 4 " s t u d s a n d n u 1 s .
Install cleanout plates (see Figure 7):
J
r278S
4
1.
F-Tt - t -Tt - I - t- | -Tt - | -Tt - B
port assemblies on front and back
sections:
l . I n s t i r l l l j ' o r r to l r s c n ' a t i o n p o r t a s s e r n b l y :
l.
r\pph' 1/8 t'ontinrrous be:rd ol-sc:rlir.rgropc adhesivt' in groo\'(' orr obst'r.r'ntion port.
lr. ['osiliorr l]/Fi st'irlirrrl ropc irr lroot's. Overlap ends
a t l ( ' i l s 1o r t t ' i t t t l r .
( ' . S c c l r n ' a s s t ' r r r b l vt o s e ( ' t i o l i .U s t ' 5 / l 6 1 8 x 3 / 4 "
slot te(l l'tt-itclscreu's.
2. Repeat abovc stcps lirr back obscn':rtiort porl lrssernbly.
Cleanout plates rnust bc installe<l gastight to prcvcnt possibility o1'tltre g:rs
leakage and carbon monclxide enrissions,
resulting in severe personal injury or death.
Position two | /4" x 1 3/4" c:rrriage bolts in cleanout
opening. Secure with washc'rs and nuts.
Place blanket lnsr.rlation piece against cleanotrt plate.
Mounl t:le:rnotrt plate over opening. Secure with nuts
anc'l washers.
Ilcpcat stcps I lhrough3 lbrremainingcleanoutplates
rNsuLArroN
CLEANOUT
PLATE --_-_
l
x'
]:.]
>\1
F -Tt - I -Tt - | -St - | - t -Tt -l -Tt - B
\\r=\\rnter. S=Stearr: F=Front. Tl=Tankless Interrnediate,
I=lntenlecli:rte. SI=Supplv Intermediate for steam boilers,
'"TI"
B=Back. "1" sections c:rn be substituted for
sections.
If you would like to pressllre-test block assembly now,
proceed to page 13.
lu'
.
".ilii
". !il i"6ir
"'"lj [- lLI
Cleanout Plate
Figure 7
9
Section C: Assemble Block
coNT'D
Mount collar on back section:
a. Remove any grit lrom threads inside tapped holes
wilh clean raq.
Install one 5/16" x l" flanged bolt hallkay into
bottonr hole in section
Rest llue collar on lizrnged bolt, making sure to
not damage gaskct.
d . Install 5/I6" x l" ll:rnQeclbolts in lo"ver two side
holes.
Tightcn all 3 bolts.
2.
Install flue collar assembly:
Make sure gasket is intact, not tom or
otherwise damaged. These conditions can
cause possible flue gas leakage and carbon
monoxide emissions. resulting in severe
personal injury or death.
Place gasket on flue collar flanged surface:
:r. Wipe all flanged surfaces with clean rag.
b. Apply rope adhesive lo enough places on top. sides
and bottom of flange to hold gaskct in place.
c. Carelully lay gasket on flue collar flange. making
strre to line up bolt holes on gasket ancl flangc.
FLUECOLTAR
FLUECOLLARGASKEI
,
IOOD MODULE
F L U EC O L t E C T O R
/[
n
a-..
@
Zll
cL'P -_-_--lvo
HoLDDowN
F L U EC O t t E C T O RH O O D G A S K E T
FLUECOLLECTOR
H O O D E N DC A P
I
g./
e,,
g
}\
*
ra'
\,"
FLAT,STITCHED
ROPE
SEATING
\i
t
Flue Collar and Flue Collector Hood Assemblies
Figure 8
t0
Section C: Assemble Block
Prepare flue collector hood assembly:
l.
2.
3.
4.
5.
Make sure gaskets are intact, not torn or
otherwise damaged. These conditions can
cause possible flue gas leakage and carbon monoxide emissions. resulting in
severe personal injury or death.
Stand one collector hood module on end.
Wipe all flanged surlaces with clean rag'
Lay gasket on flange. Refer to Figure B.
Place end cap on gasket, aligning flanged surfaces.
Secure with six 5/ 16" x 5/8" ilanged bolts and flanged
nuts. Tighten to 30 - 35 in.-lbs.
For 878 - ).278:
a. Stand remaining hood modulc on end.
b. Wipe all llanged surfaces with clean rag.
c. tay gasket on flange.
d. Carefully place open end ol'Iirst rnodule on top of
gasket, aligning flangecl surfhces.
c. Secure with six 5/ 16" x 5/8" Ilanged bolts :rncl
Ilanqed nuts.
coNT'D
6.
Attach flat-stitched sealing rope to hood assembly. See
Figure 9:
a. l,ay hood on floor rvith flanged side up.
b. Wipe flanged surl-ace rvith clean rag to remove dirt
and oil.
c. Apply double faced tape to llangecl surface'
d. Apply rope to tapc' beqinning on one side of open
end of hood, leaving | / 4" extending past edge.
Around corrlers, bend rope. do not cut. Do not
stretch roPe.
Do not pre-cut rope. Gas-tight
seal must be maintained to Pre
vent possible flue gas leakage and
carbon monoxide emissions.
resulting in severe personal
injury or death.
Continue around cntire flange. At other open end,
lc:rve 1/r1" ropc extending past eclge of flange . Cut
oll exccss ropc.
Double-{aced tape selves onlY to
hold sealir-rg rope in place during
irrsterllation. It ll.ill disintcgrate over
tinrc. Il'c'ollector hoocl and sealing
ropt- is rentovt'cl for ernv reason,
new ne\\/ tapc :ttrcl n('w gaskct
r r r r r s tb e a p p l i c c l .
TAPE
DOUBLE-FACED
APPLIED
TO FLANGE
FLAT-STITCHED
ROPE
SEALING
EXTENDROPE
I/4' PASTOPEN
ENDS
BENDROPE
DO NOT
CUT OR STRETCH
FLUECOttECTOR
HOOD END CAP
HOOD
FLUECOLLECTOR
MODULES
Sealing Rope Application on Collector Hood Assembly
Figure 9
tl
Section C: Assemble Block
lnstall flue collector hood assembly:
I
['].rct' frood on top of sections with open end of hood
trghtlv aqainst llue collar. Make sure flue collar gasket
r: in place. not broken, bent or folded.
)
In:tall 5/ l6 x 2" carriage bolts, flat washers and
rt'qultrr nuts on both sides of boiler starting at back
>r'('tion joint. continuing at each joint. See Figure I0.
'l-rehten
nuts.
'l
F.rsten hood to sections and flue collar:
ir. Slide holddown clip over carriage bolt and flange on
frood. Finger-tighten 5/ 16" flanged nut on carriage
i;olt. See Figure IO. Repeat for each clip. Where
hood joint interferes with clip installation, do not
install clip.
b. Ir.rstalland finger-tighten six 5/16'x
l" flanged
bolts and flanged nuts joining hood assembly to
f'lue collar.
( . Clentercollectorhood, makingsureitistightagainst
l}-re collar. Evenly t.ighten nuts on holddown clips,
being careful not to distort hood.
coNT'D
d.
A
Tighten six 5/16" x I" flanged bolts and flanged
nuts on flue collar to 30 - 35 in.-lbs.
Overtightening bolts in flue collector hood assembly will cause
gasket material to extrude, causing possible flue gas leakage and
carbon monoxide emissions.
resulting in severe personal
iniurv or death.
Check gas-tight seal of llue collector hood and flue
collar.
Gas light seal must be maintained to
prer.ent possible flue gas leakage and
carbon monoxide emissions. resulting in severe personal injury or death.
a. Open clamper in llue collar.
b. Check inside section assembly for any light passing
through unsealed areas.
c. Mark all unsealed areas.
d. At unsealed areas, check for damaged gaskets,
sealing rope not in place, loose bolts or nuts, or
missing holdclown clips. Correct all conditions and
repeat step b. II rrnsealecl zrreas still exist, contact
your Weil Mcl;rin clistributor or sales oflice before
continr-rin{ installation.
FLANGED
NUT
@*HOLDDOWN
CLIP
REcuLen
r.rur=--*-J>6
FtUECOLLECTOR
NOOD
FLATWASHER
CARRIAGE
BOLT
\ ,*r-,-,r.rro
___\__
S E A T I NR
GO P E
--,o rro sECo\)
Holddown Clip Installation
Figure l0
l2
Section D: Per-fiormHydrostatic PressureTest
Prepare boiler:
l. Refer to Control Tapping Table and install:
a. tsoiler drain (not furnished).
b. Water pressure gauge - for test only. Be sure gauge
can handle test pressure - see step I under "Make
test."
c. Air vent in upper tapping.
2. Plug remaining tappings.
CONTROL TAPPING TABLF
LOCATION
\^/ATER
Probe.type
Low \ /ater Cutoff
A
Skim Tapping
or
Additional
High Limit Control
B
3"
Steam Relief Valve
Water
Relief Valve
Combination
cl
I
High/Low Limit
Control
Primary Water
cr&c2
Make test:
l.
Fill boiler. Vent all air. For morc than lO minutes.
prcssure tesl.:
Steam boilers between 45 - 55 psi.
Water boilers I I /2 times working pressure.
2.
STEAM
Primary
Do not pressure test r.vith anv controls
installecl. Dantage to control can occur.
@q
stzE
Level Control
(Float.type)
Alternate
DI
Probe-type
Low \i/ater Cutoff
Back-up \ /ater
Level Control
DI&D2
3:,::i,ii:::iJ:'ilHT:i:1
:"'
(Float-type)
Firing Rate Control
(When Used)
EI
exccssive pressure, resulting in severe
personal injury, death or subst.antial
properly damage.
Check for maintained gauge pressure and leaks. Repair
il'founcl.
EI
Float-type
Low \ y'ater Cutoff
& E2
Gauge Glass
Fl & F2**
3/4"
G
l"
Try Cock Tappings
Limit Control,
tr@E f:f .ll':""'.nTxi',:::
;ff;::"11,1.
ing in subst:rntial property damitge.
Operating
Control,
Pressure
PressureTemperature
Gauge
Gauge
H
r-r /2"
Boiler Drain
Boiler Drain
Expansion Tank
:'J',Jl:i#:
ilfii:::i?,1ili,:l:tiit"*
EE@
f,:ll;.'l
liilil1lii:'::llil;:Jllff
lil:,
3.
pr()penv rlirnrlrgt..
Drain boiler and remove air vent, boiler dr:rin. gauge
liom tappings used for controls and accesso;t::.Ot"Ut
K
I
Piping or
Automatic
Air Vent
Eack-up (ONLY)
Probe-rype Water
P'
I
Level Control
(MM PS80r-r20
ONLY)
*
ll x 2 brrshing :urcl 2 phrg proviclecl with boiler.
**
[3y special rcquest onlv.
*** nP' tapping not intended 1br primary low water
cutoff
o P T t o N AtL- t / 2 '
TAPPING
OPTIONAL
INSPECTION
TAPPINGS
.-
Front Section
______'-------l
3 ^N P T
RETURN
Back Section
Figure I I
t3
Section E: Connect Water Boiler Piping
General water piping information:
. >\ rirnr rr'irtt'r sltpph' ancl return piping should be
::.ri.Lllr'clancl pipin€ connections attached to boiler
:,,-:r,r't'r.rcctir-rqjacket or installing controls.
o l), , 11,i1prpc ir.rtl-rrough supply and out throttgh return.
11)r>( r-cilles reverse water flow through boiler that nrust
I.
Connect supply and retutn piping:
a. Size according to tables below.
l ) For unknown flow rates, size piping perTable
below, using 20oF. temperature rise through
boiler.
R E C O M M E N D E DM I N I M U M P I P ES I Z E S
FOR UNKNOWN FLOW RATES*
:i,,1 ltt' Ltsetl.
o \\'itt'rr three rveryrralvesarrcused for lcmperature nlod
::i.rrron.ir-rstallslow-openin$(minimum lO-ininut.e)
'..rlvt'sanciboiler rnixing pur-npto nrinimizepotential of
:r,iit'r thcrnral shock. SeeW-M tsulletin AE U402.
I n s t a l lp i p i n g :
: . - ' . i l l p i p i n ci.t s s h o w ni n F i g u r el 2 b c ' l o wl b r s i n g l eb o i l c r s .
: - r l 5 l i ) r l l t u l t i p l eb o i l e r s .
378
2"
2"
478
2-12"
2-1t2"
3"
I
4"
778-t278
All piping sizcs b:rsetlort 20"F. temper:tlurerise
throrrgh boiler.
,t
SYSTEM
SUPPLY
( F R O N TO N L Y )
EXPANSION
F-rtr known flow rates or higher flow rate
thror-rgl-rboiler, size piping per thble below.
F-lorvat higher velocities than
shorvn in Table below lbr pipe
sizc r':ur clzrmageboiler, causinq sr rbst irnli:rl properrly
rlirrrrlqt-.
RECOMMENOED MINIMUM PIPE SIZES
FOR KNOvvN FLO\^/ RATES
TANK
WATER
I',1ETER
\^/ATER
IlANUAL
ISOLATION
VATVE
FLO\^/
SUPPLY
RATE
PIPESIZE
GPM
PRESSURE
REDUCING
VALVE
( W H E NU S E D )
5YSTEl.1
RETURN
:qONTORREAR)
RETURN
P I P ES I Z E
B
578-678
Improperrlv pipecl systcnrs or tttrclcrsizccl
piping can contribr-rte to crral.ic boiler oper:rtion ancl possible boiler or systenr clzrm:rg('.
CHECK
VALVE
SUPPLY
P I P ES I Z E
A
BOILER
MODEL
U p to 3 5
36 to 50
b.
('.
d.
RETURN
P I P ES I Z E
B
2
2"
z-t t2
z-il2"
5l to 77
J
3
78 to 142
4
4"
Loi'ate t irt'ttlirlor ilt srtpph' pipitlg.
For retrrrn pipinq. Lrsc lirll clianretcr pipe for lO
tirnes thal cliunrt'ter belorc nlakinfl any redr-tction.
For cx:rrnyrle.ii -l-int'h rettlrlt shor-rldnot bc reduced
any c'loscr to boiler r('tr.trll tapping tharn 40 inches.
Install systcnt blos'-oll (clrain) r':rlvc in lowest part
of retum pipin!. ('los(' lo ltctilcr.ASME Size requirements are shtxr.rt iIr'I-able belou'.
ASME DRAIN VALVE SIZE
BOILER MODEL
va|-vEslzE (rN.)
378 - 478
lt4
578- il78
Water Boiler Piping
Figure 12
l4
t278
t-U4
Section E: Connect Water Boiler Piping
2.
Install expansion tank:
a. Closed Q,pe - connect to l " tapping "K" (rel'er to
Control Tapping Table, page l3). Use l" N.P.T.
piping. Any horizontal piping must pitch up toward
tank at least I inch per each 5 feet of piping.
b. Diaphrergm [pe - Refer to tank manufacturer's
literature for location. Install automatic air vent in
"K" tapping.
c. Connect cold water fill to expansion tank piping.
See Figrrre 12. Also shown are recommended valvcs
and water meter. when used. Water mcter will
detect added make-up water, inclicating lezrks in
svstem.
I']iping for nrrrltiple boilcrs (st:c Figurt-' 13):
Q!
boiler punrp GPM baseclon lbllowSir.'st'r'orrclary
ing lornrrrl:rs:
( ; I I O S SO L ' 1 - I ' L 'I1\ ' I } . I ' It-]
TEMPERATURE
RISE IN oF x irOo
=
Cll'\1
coNT'D
Calcul:rte only secondary piping circuit resistance.
Boiler resistance will be about equal to three 90degree elborvs ol'secondary pipe size.
Operate each boiler and its secondary pump from
EMCS system. Do not maintain boiler at predeternrined'uv:rter temperature.
Prirnarl'punrp GPM and head calculation should
not include secondary boiler circuits. Primary
pump can operate continuously during heating
sc'ason.
(9/
@
@
Space 12" maximum or as close as practical
Check valve.
I l:rrrrl valve.
l'-xpirrrsiorrtrrnk(s). reliel-r'alves and other accessories
irrc re'rllrirt'cllrut ttot shovu.n.
NOTE: TEMPERATIJR-ERISE IN.F=
23OOF- RETI,JRNWATER TEMPERATURE
Multiple Water Boiler Piping
Figure l3
t5
Section F: Connect Steam Boiler Piping
General steam piping information:
o Hartlbrd l-oop piping arrangement and wet return are
reclr-rirecl
lbr steanr boilers.
o \liiinlain 2-l-inch minimum from waterline to bottom of
hcadcr (56- I /.1 liom bottom of section).
o \\'hen usir-rg condensate receiver, feed pump musl be
cnc'rqizcd bv boiler-mounted pump controller.
COLD
WATER
FLL
Install piping:
Install piping as shown on page I7 for single boilers, page
l9 for mullipleboilers.
Improperly piped systems or undersized
piping can contribute to erratic boiler
operation and possible boiler or system
darnage. Piping system must be installed
as shown, usingpipe sizesshown. Consult
local Weil-McLain distributor or sales
ollice belbre installing alternate piping.
PRESSURE
REDUCING
VALVE
supply :rnd return pipit-tg:
1:rblc below:rnd:
Sizt' lorc'eclconclens:rte retlrrn piping by ptlnrp.
Sizc gravitv conclensate return same as equal
izer "J" pipc size.
Ir-rst:rll svstenr dr:rir-r .,':rlve in lowest part of rclurn
piping close to boilcr. ASME size requiremenls are:
shown in Table. pagcr I4.
Conncct colcl water lill piping ers shown in Figure
14. Also shown are recomnlcnded valves and water
metcr. il'usecl. Water nreter will ck-'lecl.aclded maketrp water, ir-rdit'atir-rgleaks in systenr.
Connect
:1. Scc
I)
2l
I'lANUAt
TO CONDENSATE
RETURNP1PING
ORCONDENSATE
RECEIVER
lt.
(sEE
FrG.
r8,
PAGE
r8)
Cold Water Fill Piping
Figure 14
STEAM BOILER PIPE SIZE TABLE
B A S E D O N 2 . P I P ES T E A M S Y S T E M
*RISER
P I P ES I Z E - I N .
H
HEADER
tN.
t
FIG.
NO.
BOILER
MODEL
A
t5
378
3
3
2
t5
478
4
4
2
t5
578
4
4
2-U2
t6
678
3
l
4
2-U2
t5
778
4
4
4
2-t t2
t6
878
4
4
4
3
l6
978
4
4
6
3
t7
| 0 7 8 -| 2 7 8
4
4
6
3
B
c
4
tN.
Based on ASHRAE Handbook recommendations, allowing 1/2 oz.
pressure drop per 100 leet ofpipe for dry return.
Based on ASHRAE Handbook recommendations, allowing 2 oz.
pressure drop per IOO feet of pipe at 3.5 PSIG. Maintain minimunr
24" heishl from waterllne to header
t6
Section F: Connect Steam Boiler Piping
coNT'D
,
SUPPLY
SYSTEM
SUPPLY
SYSTEI,l
HEADERPIPE
S I Z E" H ' '
RISERPIPE
S I Z E" A
24"t'4tN.'
24" t'1tN.'l
FULLSIZE
ORREDUCING
ELBOW
4'MlN.
TO
IOP
OF
PIPE
RISER
SIZE"8"
FULL
SIZE
ORREDUCING
ELBOW
EQUALIZER
S I Z E" j "
PtPE
4"tltN
TO
TOP
OF
PIPE
CLOSE
NIPPLE
EQUALIZ
ER
"J'
PrPE
S|ZE
. closE
'i*ou,r,
NIPPLE
.\
CONDENSAII
RETURN
.GRAVITY
CONDENSATE
RETURN
*24" minimum from water line to bottom of header
378 through 578
Steam Boiler PiPing
Figure 15
*24" minimum from water line to bottom of header
678 through 978
Steam Boiler PiPing
Figure l6
SUPPLY
SYSTE14
HEADERPIPE
ELBOW
FULLSIZEOR REDUCING
'J"
PIPESIZE
EQUALIZER
RISER
'c"
srzE
BACK
OF
BOILER
CLOSE
NIPPLE
t--'
. GRAVITYCONDENSATE
RETURN
*24" minimum from water line to bottom of header
1078through 1278
Steam Boiler PiPing
Figure 17
t7
Section F: Connect Steam Boiler Piping
cot{T'D
C'ottclt-tts'rl
c pipiltg:
Satisllrc'ton'operation of anv steam heating system depends on adequate return of condensate to maintain steadt-u-ater
level. Avoid aclding excessive amounts ol raw make-up water. Where condensate return is not adequate. a low. rvater
crttoll'nitl-t pump control, cond:-nsate receiver, and condensate boiler feed pump should be installed. Refer to Figure l ir
lor pipine arnd to Condensate Receiver Capacity Table for sizing.
SYSTEM
CONDENSATE
RETURN
I
V
ATMOSPHERE
TO EOILER
CONDENSATE
REIURN
@
@
COLD WATERFILL
. S E EF I GI 4 .
PIPING
P A G E1 6
o
@
totrol tsoLATtoN
vALVE
STRAINER
FEEDPUI'.1P
CHECK VATVE
Condensate Piping to Boiler
Figure 18
C O N D E N S A T E R E C E I V E RC A P A C I T Y T A B L E
BOILER
MODEL
l=B=R
GROSS
OUTPUT
LBS.
STEAM
PERHOUR
378
278
478
M I N I M U M C O N D E N S A T E R E C E I V E RC A P A C I T Y - G A L .
60 MtN.+
BOILER
OPERATION
RECOMMENDED
CONDENSATE FEED
PUMP
CAPACITY GPM
AT I5 PSI
ll
4l
t.l
29
44
58
t.6
t9
38
57
76
2.1
77
24
47
70
93
2.6
754
92
28
55
83
ill
3 .1
878
886
r06
32
64
95
127
3.5
978
| 007
t2l
37
73
t09
t4s
4.0
I078
| 129
t36
4l
82
t22
r63
4.5
I t78
|250
t50
4S
90
t35
r80
4.8
1278
1372
t6s
50
99
t49
r98
5.4
t5 MtN.*
BOILER
OPERATION
30 MtN.*
BOILER
OPERATION
34
ll
2l
400
48
t5
578
521
63
678
543
778
GALLONS
CONDENSATE
PERHOUR
Maximum time to when condensate returns to boiler.
t8
45 MlN. *
BOILER
OPERATION
Section F: Connect Steam Boiler Piping
)
3.
Multiple steam boiler piping with graviff condensate
returrr:
Install boiler feecl pump or solenoid control on each
boiler with body mark at level indicated on page 23.
Use:
Separate feed pumps and check valves lbr
o
each boiler, or ...
o
Single I'eeclpump and separate solenoid valves
for ear:h boilcr.
Install combitration lloat and thermostaticr trap on
ezrch boiler t.o prt:vent llooclirlg of onc boiler while
other boiler is {lring. For 78 boilcr, install trap irt
skinr tapping (soc pitgc 22). Clortrtectf r:r1ls ttr
condensate rcceivcr.
(p
coNT'D
( D ) tnstall stop valves per ASME code requirements
\_-/
and slow-opening automatic steam valves when
used. Use EMCS system to open automatic steam
valve befbre firing burner.
( E ) Construct common supply drop header with pipe
size at learstsame size as largest boiler header size.
Use:
. EMCS system with header-mounted pressure
control(s)to sequcnceboilcrs. OR
o Steam pressurc controller.
(G ) tnstarll dr-ain lirte in common supplv drop hcader'
Ut" tonrbittittiotr flo:rt antl thenrltlstatic trap ancl
clrain ttt cottcletts:ttcrccciver.
Install l;oiler ltilling as shoun irl lloiler tn:rtrrtrtl.
Multiple Steam Boiler Piping
Gravity Condensate Return
Figure 19
l9
Section G: InstallJacket
lnstall Jacket:
1. f)ackaqecl boilers - install top jacket panel.
'2. Non-packaQed
boilers - refer to instmctions packed in
.j:rcket canon. The following must be complete before
.jat'kct is installed:
o ltoilerl-r'u'drost.aticallypressure-tested. Seepage 13.
o plr.res lbr unused tappings installed. See Control
Tapl;ing 1'able. page 13.
supply and return piping installed. See paqes l{
through 19.
cleanout plates, flue collar and flue collector hood
installed. See pages I - 12.
Section H: Pipe TanklessHeaters
To pipe tankless heaters:
l. Size ltiping no smaller than heater inlet arrd outlet.
2. Autonr:ltic mixing valve must be inst.allcd. See Figure
20. Follorv manulircturer's instructions to install.
ll. F-lou,regulating valve ntust be installed. Size according
to conlinuous draw of heater. See Table below. Follow
nranulhcturer's instructions to install.
4.
5.
TANKLESS HEATER RATINGS TABLE *
TANKLESS
HEATER
MODEL
CONTINUOUS
DRAW GPM
INLET AND
OUTLET
TAPPINGS
78-24
6.5
3t4"
6.
Operating control with small ad-iustable dilferential
scale is recommended. Install in tempererturc control
tapping in he:rter plate.
Multiple tanklcss heaters (see F-igtrre 20):
a. Use colcl water supply header with individual rist'rs
to each healer. Size heacler by increasing one pipt,
size lbr cach aclditional hcater.
ir. Use hot water outlet lre:rclerwith individual riscrs
to each healcr. Size heaclt:r by increasing onc lti1tt'
size lbr c:rch additionzrl heater.
c. Do rrot pipe nrultiple heaters in series.
In hard water areas, sollen cold domestic supply warcr
to heaters to prcvcnt lime build-up.
GPM hcatccl frorn 4O')F to lzlOoF (lOOoli lcmperature
r i s e ) w i t h 2 O O 0 Fb o i l e r w a t e r t e n t p e r a t u r e .
Continuous clraw no recovelv oeriod.
ALTERNATE
t.'
../
TO AUTOIlATIC
I'IIXINGVALVE
AND PIPING
ALTERNATE
Tankless Heater Piping
Figure 20
20
Section l: Install Water Boiler Controls
Install controls:
l. Install furnished controls where shown in Control
Tapping Table and Figure 2 t.
Failure to properly install, pipe and
wire boiler controls can result in
severe damage to boiler, building and
personnel; and is not coveredby boiler
warranty.
2 . Relief valve must be installed with spindle in vertical
.).
4.
5.
6.
Dual limit control settings:
o l,ow - set according to design requirements.
o High - at least 20" higher than low limit, 24OoF.
ma)aimum.
Install optional controls per control manufacturer's
instructions.
position. Use fittings provided with boiler. Do not make
any other connection in that piping.
Relief valve discharge line must be
pipecl near floor close to drain to eliminate potential of severe burns. Do not
pipe to any area where freezing could
occur. Do not plug. valve or place ar-ry
obstruction in disch:rrge line.
When installing low rv:rter cutoff:
a. Must be installed ilboiler is loc:rted :rbove racli:rtion
level.
b. May be required on water boilers by certain sta1e.
Iocal or territorial codes or insurance conrpanies.
c. Install low water cutoffdesigned lor water installa
tions where shown in Control Tapping Table and
Figure 21.
If installation is to comply with ASME instzrllation
requirements, an additional high temperature limit is
needed. Purchasc and install in supply line between
boiler ancl isolation valve or in tapping 'A."
4" NPT
SUPPLY
WATER CONTROL TAPPING TABLE
LOCATION
stzE
A
3"
B
3"
FUNCTION
Primary Probe-type Low
Water Cutoff or Aditional
High Limit Control
Water Relief Valve
CI
I
Combination High/Low
Limit Control
DI
I
Alternate Probe-type
Low Water Cutoff
DI&D2
l"
Float-type
Low Water Cutoff
EI
I
Firing Rate Control
(When Used)
G
I
PressureTempture Gauge
H
L-L/2"
Boiler Drain
K
l"
E x p a n s i o nT a n k P i p i n g o r
Automatic Air Vent
4" NPT
SUPPLY
3 ' N P T.
RETURN
3'NPT
RETURN
Front Section
Back Section
Water Control Location
Figure 2l
2l
Section J: Install Steam Boiler Controls
lnstall controls:
I
Inst:rll controls r'vhereshown in Control Tapping Tzrble
iurd Figure 22.
il.
lt.
Failure to properly install. pipe ancl
wire boiler controls cal result in
severe damage to boiler. buildir.rq:u.rcl
oersonnel: and is not r:overed bv boiler
warranq/.
Install steam pressure operating anci high linrit
r:ontrols and pressure g:luge. See Figurc 23. I)rcssure limit control settings:
Low - set according to clesign reqtrirements.
o
High - set at lcasl 2 psi highcr than low linrit.
.
I5 psi ma-ximum.
Rc-licl-valve must be installed with spinclle in vertical position. Use fittings provided with boiler. Do
not make any ot.her connection in that piping.
Pipe reliel valve discharge throtrgh
verlical piping to atnrosphere.
Install drain pan clbow to drain
condensate. I)ipe near floor close
to lloor drain to elinrinalc polc'ntial ol-scvercbtrrns. Do r-rotpipc to
any area where lreezing cotrlcl oc'
crrr. [)o not phrg, v:ilr.t. or placc
ilnv obsttuction in clischarge line.
Install water level controls ancl gauge gl:rss :rs
shown in Figure 24.
l) Irittings for controls to ber ft-rrnishcd by
others.
2)
I1\\'atcr Ie\'el control is not shorr,'nin Figure 24
orr'bociv rnark on control and
i n s l i r l l 1 ; t ' r n L i r t r r l l rttu r t ' r s i n s l n l c t i o n s .
lot rtlt' t rtsl
:',l.ill':,ill';l,i:l;1,;
trlEil li:],
l ) t t i n q s . \ r r r s : u t r r : h L r lc l o r i r r s
r','ill occur.
STEAM CONTROL TAPPING TABLE
LOCATION
stzE
A
'3"
Skim Tapping
B
3"
Steam Relief Valve
cl&c2
l"
Primary Water
Level Control (Float-type)
DI&D2
l"
Back-up \ y'ater Level Control
(Float-type)
FUNCTION
EI&E2
l"
Gauge Glass
Fl & F2.-
3/4"
Try Cock Tappings
G
l"
Limit Control, Operating
Control, Pressure Gauge
H
L-r/2
I
Boiler Drain
Back-up (ONLY) Probe-Type
\ /ater Level Control
( M M P S 8 0 t - 1 2 0O N L Y )
iJ' x 2 lrtrshing ancl 2" pltrg proviclecl w'ith boiler.
Fiv spec'ial rellrest only.
"P" tapping not intencled lbr primary low watcr
cutolT.
]PTONAL
\,iaEcTtoN
IAPPINGS
3' NPT
RETURN
Back Section
Front Section
Steam Control Location
Figure22
22
Section J: Install Steam Boiler Controls
PRESSURE
GAUGE
coNT'D
FIRINGRATE
CONTROL
(WHENUSED)
Steam Control Siphon and Fittings
Figure 23
WATER LEVEL CONTROL LOCATION TABLE
PRIMARY
WATER
LEVEL
CONTROL*
6 l 63
CASTING
LINE
HEIGHT
ABOVE
BOTTOM
OF GAUGE
GLASS (A)
il2"
BACK.UP
\^/ATER
LEVEL
CONTROL*
6t,63
CASTING
LINE
HEIGHT
ABOVE
BOTTOM
OF GAUGE
GLASS (B)
lt2"
42, | 50MD,
I57MD
2-3l8"
6t,61
BACK.UP
(oNLY)
PROBETYPE
WATER
LEVEL
CONTROL
tN "P"
r-t
o
TAPPING
MM
PS80t-t20
U2"
MM
PS80l-t20
BACK-UP
WATER
LEVET
CONTROL
B-
T
A
PRIMARY
WATER
LEVEL
CONTROL
T
TAPPING
9 3 ,r 9 3
t-3t4"
6 l 63
u2"
MM
PS80t-t20
2-5t8"
6 l 63
U2"
MM
PS80t-|20
5r-2,5t-S-2
t<
*r.
BLOWDOWN
VALVE
Other manufacturer's controls providing similar Iunction may be used. if properly loc:rted ancl selected,
Cannot be used as backup water level controls.
When pump control is used with fecd watcr tank. install
pump control on boiler and make-up nater f'eeder on
tank. Use separate low water cut oll-on boiler r,"'henback
up is needed. Do not install combination low water cutoff and feeder as back-up control on boiler. Feecler will
operate before pump control operates.
Water Level Control Location
Figure 24
23
Section K: Connect Breechingand Venting Systems
General venting information:
o 7E boilers operate u.ith overfire positive pressure.
Acljrrst breeching damper in flue collar (see page 26)
cltrdnq burner start-up to achieve 0.1' W.C. positive
pressr.lre at llue collar.
Construct metal breeching:
o See back cover for minimum breechinq cliatttctcr.
. Select material type and thickness in conrplialrce \\ilir
local codes.
Select type of venting system:
o Forced draft IJoiler. brcec'hing and stub vent operate at positive pressLrr(..Entire svstem mrrst be gas-tight to prevent leaks.
Stub vent hci{ht must be limited to prevent negative
clr.rli n'ith 3-foot minimum stub vent height above roof.
See Fi{ures 25 and 26.
r Balanced draft -
carbon monoxide emissions through
seams and joints, resulting in severe
personal injury or death.
Rel'er to ASHRAE Guide for chimney and breeching
calculations and construction and lining.
Iiriler operntes with posilive pressure overfire. Chimne\- may provide excess draft which may require a bar
oni('tric clrall crontrol installed and set to providc min
irnrrnr clr:rl1to maintain 0.I" positive pressure at {lrre
collirr. Minimtrm r:himney height al;ove roof is 3 fcct.
St'r' F-igrrrcs27 and28.
Stub Vent - Forced Draft
Single Boiler
Figure 25
24
Stub Vent - Forced Draft
Multiple Boiler
Figure 26
o
E@
"
l-ff:::11
:::J::'i?::1,ffi
"":::
E@
."J;,T:i""
ff#:1i:::'lfi'":t'tr:
obstrr,rctions restrictino combustion
{as llow can rcsull in possibility of
condensatiott. llue gas lcakage ernd
c:rr'bon nronoxide enrissions. causing
severe pcrsottarl injr-rry or death.
Conventional Chimney - Balanced Draft
Barometric Draft Control When Required
SingleBoiler
Figure 27
Conventional Chimney - Balanced Draft
Barometric Draft Control When Required
Multiple Boiler
Figure 28
Section L: Install Burner
To install burner:
i. Unpack burner.
2. Placegasketaround air tube and against burner mounting flange.If sealingrope is used. applv l/S" continuous beacl of rope adhesive arotrnd burner mounting
flange :rnc1:rpplr. sealing rope to make gas-tight seal.
3.
4.
5.
6.
Mount burrrer into opening in burner mounting plate.
@
;H".:*ffirf,+iH$
I-evelburner using burner support brackets where
required.
Secure with furrrished bolts.
Retain bumer information packet. Keep with boiler.
Section M: Wiring and Fuel Piping
Electric shock haz:rrd. Can cause sc'vere personal injury or cleath if power sorlrce is nol clisconnccted
bcfore installing or scn'icing boiler and burner.
To wire burner and boiler controls:
l.
Install all wiring in compliance with:
o National Electrical Code ANSI/NFPA 70.
o Any additional national, state, or local codes.
2. Follow burner manual and wiring diagram ibund in
burner inlbnnation packet.
3. Use 14 ga. wire lbr oper:rting and safety circuit wiring.
4. Where burner motorvoltage clilfers from control voltage,
supply proper voltage to each. Size fuscd disconnectfs)
and conductors per National Elcctric:rl Code ANSI/
NFPA 70.
To install gas and/or oil piping:
1. h'rstall all piping in compliancc with:
o Local, sterte or nation:rl codes aud re$ulatior-rs.
o Separate burncr manuzrl pror,'ided with btrrner.
2. Use pipe joint compound (pipc clope) rcsist:rnt to corrosive:rr:tion ol.luel oil or liquiliccl petrolerum gascs. Apply
sparingly to male threads ol pipe.joints. Do not use any
kind of pipc tape.
3. Oil piping use flare-type littings, not c'ompressiontype.
Do not use compression or soldered
Iittings. No sal'e repair can be made.
Sevcre personal injury, death or sub
st:rntial property danrage rvill rcsult.
25
Section N: Make Final Adjustments
To fill water boilers:
t l, ):t' ntilnLlal air vents and dr:rin cocks.
.
I
Flll to (orrect svstem pressure. Corect pressr-rrcu,ill
\.u1 \\'ith e:rch installation.
.l Sl.rrtinq on lou,'est floor, open air vents one at a time
rurt il s':rter squirls otrt. Close rrent. Repeat with remainlne \.cnts.
+. Ilcllll boilcr to correct Dressure.
To fill steam boilers:
I . Do not lill (excepl for leakage test) until boiler is ready
to be lirecl.
2. Fill to normal waterline. hailway up gauge glass.
il. l{t'conrnrcnd boiler water oH 7.0 to 8.5.
Adjust burner and breeching dampen
l.
2.
3.
4.
5.
6.
7.
B.
\ l . r k e I - i n . rlll r r n r c r . r t l j r r : l r r r t r r t :r r r r r r q
conrbustron test equipment to assrlre
proper operation. Do not lire boiler$-itl-rotrt
water. Sections will overheat. damaging
boiler and resulting in severe property
danrage.
lock open breeching damper.
Refer to bumer manual for start-up and service.
Irt bumer advance to high fire. Heat boiler to design
conditions.
Using combustion test equipment, ad.jusl burner [or:
:r. l2o/o @ | / 4o1o)CO, for No. 2 fuel oil, O smoke.
b. 9 - lO%, CO, n:rtural gas, CO in flue gas to not
exceed IOO ppm (O.Ol7o).
Adjusl brccching damper to assure O. l " W.C. positive
pressllrc nt test opening. Secure darmper.
Adjust barometric draft control, whcn trsed, to design
conditions.
Check per sle'ps 4 through 6. Adjust as required.
l'}lug test opening with I /8" brass plug.
BREECHING
DAI'4PER
(sLlDE
DOWN TO
OPENDAI1PER)
Breeching Damper Adjustment
Figure 29
25
SectionN: Make FinalAdiustments
Skim steam boilers:
Clear-rnl1neulr'ir.rst:rllsteanrboilers to
remo\-c oil. Failtrre to properlv clean can
resr.rlt in riolent u'ater lcvel fluctuations.
\\'lltcr prlsslnq into steanr mains. or high
n l i r i n l (l t i r n c e( ' o s t so n s t r a i n c r s .t r a p s a n d
vents. Skim boiler only. Do not clean old
piping or ieaks can occur.
Do not use petroleum-based cleaning or
sealing compounds in boiler system.
Severe damage to systcm components can
result.causingsubstantialproperlydamage.
l.
2.
3.
4.
5.
Remove 2" plug lrom 3" x 2" bushing at skim tapping.
Provide 2" skim piping liom tapping to lloor clrain.
Raise waterline to midpoint of skinr piping.
Fire burner to m:rint:lin lenrperature bclow slcatning
rate cluring skirnnring proccss.
Fced in water to maintzrin water level. Cvcle bttrncr tcr
prevent rise in steam prcssure.
-l-his
rnerv
Continue skimming until discharge is crlear.
Determine if water treatment is needed (water boilers
only):
Do not use petroleum-based cleaning
or sealing compounds in boiler system.
Severe damage to system components can
result, causing substantial proper$z damage.
Continual make-up water vrill reduce boiler life. Minerals
can build up in scctions, reducing heat transl.er, overheating cast iron and causing section lailure.
For unusually hard water areas or low pH conditions (less
than 7.0) consult local water treatment cornpany.
Freeze proteclion (wher-r trscd):
I.
Usc arrl.ilieeze espccially rnade lbr hydronic systems
I nhibit cc'l propylenc Slvcol is rec'ommt-'nded.
Do rrol use atrtomotive . ethylene glycol
or rrnclilr-rteclantifieezc. Severe
personal in-jury or death can result.
2. SO(/osolr.rtion providcs protectiotr to about -3OoF.
3.
take several hours.
6.
7.
Drain boiler. While boiler is warm but not hot, llush all
interior surfaces undcr Iull pressr.rre unt.il drain rvater
runs clear
Remove skim piping. Re insert plug at boilcr skinr tap-
prng.
B. Close drain cock. Fill with liesh water to norrnal waterto remove
Iine. Start burner :rnd stearn for I5 n.rir-nrles
9.
4.
5.
lncal codes rnery recltrire back-llow prevenlcr or act.ual
clisconnect lrom citv rvater sttpply
Determine qr-rantitlzaccording to systen.r water content.
Boiler water content is listccl on page 30. Percent of
solution will allect sizing ol-heat distribution units,
circulat.or and expansion t:rnk.
Follow zrntilieeze manulh<'trrrt'r's instntctions
Check boiler for gas-tight seal:
dissolved gases. Stop burner.
Chcck traps and air vents lirr proper operalion.
l.
2.
3.
4.
Boiler nrust bc scarledgas-tight to prevent
possible Ilue gas leakagc and carbon monoxidc emissions, resulting in severe
personal injury or cleath.
Remove boilerjackct sicle and top pancls.
Start burner. Obserruc all sealing points and chalk
mnrk any r-rotgas-tigh{.
To seal all chalk marked areas:
a. use siliconc sealant on section flut--ways.
b. cl-rccrkgaskets ancl sca.ling rope placement.
Reinstall all jacket panels.
27
Section O: Data and Dimensions
DATA
DIMENSIONS
SUPPLYTAPPINGSQUANTITY
AND SIZE*
R E T U R NT A P P l N G S .
QUANTITY
AND SIZE*
BOILER
MODEL
WATER
STEAM
WATER
STEAM
378
2-4"
2-4"
2-3"
2-3"
478
2-4"
2-4"
2-3"
578
2-4"
2-4"
578
2-4"
778
E
t3-t/8
8
42-U2
2-3"
20-18
I
4 2 - u 2 20-U2
27-3t8
28-U2
2-3"
2-3"
2 7- t I 8
8
42-t t2
27-U2
34-3/8
35-t 12
2-4"
2-3"
2-3"
34-tt8
8
42-t t2
, 4 - t1 2
4 | -3/8
42-u2
2-4"
2-4"
2-3"
2-3"
4 t - tt 8
l0
4t -t 12
4t-u2
48-3/8
49-t t2
878
2-4"
2-4"
2-t"
2-3"
48- | /8
t0
4t-U2
48-tt2
55-3/8
s5-tt2
978
2-4"
2-4"
2-3"
2-3"
5 5 -| / 8
t0
4t-U2
5 5 -| / 2
62-y8
53-t t2
| 078
2-4
3-4"
2-3"
2-3"
62-t t8
27-18
t0
4l lt2
AA
U2
69-3/8
70-t t2
I t78
2-4"
3-4
2-3"
2-3"
6 9 -| / 8
3 4 - tt 8
t0
4 l |2
69-|t2
76 - 3 t 8
7 7 U2
1278
2-4"
3-4"
2-3"
2-3"
7 6 - tt 8
4t-rl8
t2
4 0 - tt 7
76-U7
83-3/8
84-tt2
* Use piping connections shown in manual, pages 14 - 19.
28
w
D
A
B
H
L
r 3 - t / 2 20-3/8 2 t - u 2
Section O: Data and Dimensions
"\
Gr \
Err\
--
coNT'D
r_ 101,4"
l_4 a_4 1tz"
\ l l ' ' lI
D1
F1
tr
2
c
D^
I'Nn
RETURN
Back
f,
,.E
L..'::'.
Side
Intermediate
29
Section P: Parts
I
I
qk:.-.
-@ (9
@@
@d
./v)
,/
,/
,/
,/
,/
-\
G),---1+>M,)
\-/
Y !1 /l
(N)--\-/
30
-,4
I r -..1
.rr
. \
l)) |
/-
ffi*
t
Section P: Parcs
o
DESCRlPTION
F I G U R EN O .
W-M SALES REF.
NUMBER
F R O N TS E C T I O N( 7 8 I 3 )
I I8329
I N T E R M E D I A TS
E E C T I O NR E G U L A R( 7 8I 5 )
| |8330
I N T E R M E D I A TS
E E C T I O NS U P P L Y .S T E A M( 7 8 I 4 )
ItB33l
I N T E R M E D I A TS
EE C T I O NT A N K L E S S( 7 8 I 6 )
| |8332
(78r8)
BACKSECTTON
| |8333
Y I T ( i n c l u d e fso r o n e j o i n t - s e a l i n gr o p e ,s e a l i n gr o p e a d h e s i v es,e a l i n gr i n g s ,
S E C T I O NA S S E M B L K
s i l i c o n es e a l a n t ,i e r o d s ,w a s h e r sn, u t s )
| | 8334
E
HEATERCOVER PLATECARTON (includescover plate,gasket,studs,nuts)
I r 8335
F
, a s k e ts, t u d s .n u t s )
T A N K L E S SH E A T E RC A R T O N ( l n c l u d e tsa n k l e s sh e a t e r g
| |8336
HEATERGASKET
I I 8302
C L E A N O U TP L A T E
| |8337
CLEANOUT PLATEGASKET
| | 8304
F L U EC O L L E C T O RH O O D " A "
I r8 3 3 8
F L U EC O L L E C T O RH O O D " B "
| |8339
''C"
| | 8340
F L U EC O L L E C T O RH O O D " D "
I tB34l
HOOD"E"
FLUECOLLECTOR
I tB35t
FLUECOLLECTOR HOOD HARDWARE KIT (includesflat-stitchedsealingrope. double-facedtape,
flue collar gasket,collector hood gaskets,holddown clips,hardware)
| | 8342
K
COLLECTOR HOOD GASKETKIT (lncludesflue collector hood gasket,flue collar gasket,flat-stitched
sealingrope and double-facedtape)
il83rl
L
F L U EC O L L E C T O RH O O D E N D C A P
| | 8343
F L U EC O L L A RA S S E M B L8Y' '
| | 8344
IO
F L U EC O L L A RA S S E M B L Y
| | 8345
I2
F L U EC O L L A RA S S E M B L Y
| | 8346
COMBUSTION CHAMBERKIT (includesback refractoryblanket,bottom refractoryblanket,
waterglass,sealingrope, sealingrope adhesive)
| | 8348
B U R N E RM O U N T I N G P L A T EF R O N T R E F R A C T O R Y4 - I / 2 " B U R N E RO P E N I N G
| | 8349
B U R N E RM O U N T I N G P L A T EF R O N T R E F R A C T O R Y6 - I / 8 " B U R N E RO P E N I N G
| | 8350
o
REFRACTORY
R E T A I N E RC L I P
| 08960
r
p o r t a s s e m b l ys,e a l i n gr o p e ,s c r e w s )
O B S E R V A T I O NP O R TA S S E M B L (Yi n c l u d e os b s e r v a t i o n
| | 8300
S E A L I N GR O P E
|08985
B
D
o
F L U EC O L L E C T O RH O O D
M
N
f
3l
o
tt
l=B=R Burner
Capacity
Boiler
Model
tl
G ross
l=B=R
Light
OT
oil
GPH
MBH
Output
MBH
T
Steam
MBH
Positive
MBH
Packaged
Boiler
Weight
Pressure
ln
l=B=R
Vent
Dia.
CF14
Firebox
I n .W . C .
Steam
to
In cn e s
Waterline
7.61
t39
0.22
8
37.5
27.5
|355
Boiler
Net
F ir e b o x
Volume
Volume
H.P.
Cu. Ft.
8.3
I
Steam
Sq. Ft.
Boiler Water Content
Gals.
a
Net I=B=R Ratings
Stack
LessWater
LOS.
a
- 3 7 8 - +oF
2.40
346
278
871
209
a
- 4 7 8r-' F O
3.40
494
400
|250
300
348
il.9
3.97
t98
0.22
8
49.0
360
t6t5
A - s z e - * 3r
4.45
641
521
| 629
391
453
|5.6
5.33
259
0.21
I
60.5
44.5
|875
a
- 6 7 8 - * Fa f
5.50
789
643
2008
482
559
19.7
6.69
120
0 . 2I
8
72.0
53 . 0
2t30
L
- 7 7 8 - * Fa
6.50
937
764
2388
573
664
22.8
8.05
378
0 . 2|
t0
83.5
6r.5
2390
A
-878-'F O
7.50
| 084
886
7 7 7|
665
770
76.4
9.41
436
0.20
t0
95.0
700
2650
L - w a - * r1
8.50
1732
| 007
3t54
755
876
3 0 .I
t0.77
494
0.20
t0
t06.5
785
2 9t 0
a - 1 0 7 8r '-Fa
9.60
1379
I t29
3533
847
982
t2.t3
558
0.20
t0
I t8.0
87.0
3t65
|0.60
| 527
|250
3 9t 7
938
| 087
37.3
t3.49
6t6
0.19
t0
129.5
95.5
3425
| 674
1372
4321
|039
I t93
4t.0
14.85
675
0.t9
t2
t4t.0
104.0
3680
^.
I t 7 8 -* F o
A -1278-+FO |.60
Use prefix "BL" for lightoil, "BG" for gas,"BGL" for gas-lightoil, or "H" for boileronlyfor usewith approvedburners.Add prefix"A" to designator
78 (ABL-478).Substitute"P" for "8" for fire-testedpackageunit (PL-478).
for factory-assembled
'r' Substitute"S" for steam,"W" for water.
For T-lntermediatesection(s)and tanklessheater(s)add suffix"(number required)TlH"; for T-lntermediatesection(s)with cover plate(s)only
O
add suffix"(numberrequired)TlP".
a
Burner input basedon maximumof 2,000feet altitude- for higher altitudesconsultWeil-Mclain represencative.
,"k No.2 fuel oil - CommercialStandardSoec.CS75-56.Heat valueof oil - 140,000Btu/Gal.
required.
ConsultWeil-MclainBURNERSPECAND DATA SHEETfor gaspressures
)
I
MBH refers to thousandsof Btu oer hour.
f
Gross l=B=R ratingshavebeendeterminedunder the l=B=R provisiongoverningforced drafcboiler-burnerunits.
tt
Net l=B=R ratingsare basedon net installedradiationof sufficientquantityfor the requirementsof the buildingand nothingneed be added
for normal pipingand pick-up.Water ratingsare basedon a pipingand pick-upallowanceof 1.15.Steamratingsare basedon the following
allowanceshouldbe madefor gravityhot water systemsor for unusualpiping
378through | 178- 1.333;1278- 1.32l.An additional
allowances:
and pick-uploads.ConsultWeil-Mclainrepresencative.
'i''i 'kScackgasvolume at outlet temperature.
1
at flue collar.
With 0. 10"W.C. DositiveDressure
A
Note: Sectionstested for 60 PSIGworking pressure.Water boilersavailableupon specialrequestat 80 PSIGworking pressure.
lllHl'mrnlll
Dominion
AUnited
Company
Weil-McLain
Street
500Blaine
Michigan
City,lN 46360-2388