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Home My WebLink AboutCORRESPONDENCE - PURCHASE ORDER - 9164184G:\LONG Hydronics\Jobs\Edora Pool Ice Center\4 - Proposals\BOILER QUOTE - EPIC Boiler Replacement 6.2.16.doc Colorado Nevada Utah Wyoming Technology for Better Buildings…Since 1965 to: Zac Smith June 2, 2016 company: City of Fort Collins delivery terms: FOB Factory. Freight allowed to first destination. from: LONG Hydronics/Plumbing payment terms: Net 30 days (with credit approval). Otherwise cash. regarding: Edora Pool Ice Center [EPIC] Boiler Replacement order acceptance: Conditional on the terms and conditions attached. If you do not have them, please request a copy. We are pleased to quote the following equipment based on the PLANS ONLY dated 4/21/16, and the following qualification: 2 Buderus Cast-Iron Boilers  B-1-2 Model: G615/14  4650 MBH Input / 3200 MBH Output at Elevation of 5000 Ft.  Riello RS130/M NG Burners w/ RWF 55 controller  2010 ASME Code Compliant listed for 87 PSI  UL Listed  480V/3ph  Hydrolevel Probe Type Low Water Cutoff w/ Manual Reset  ASME Pressure Relief Valve  T/P Gauge  Manual Reset Temperature High Limit Safety  Multiple Point Power Connections  Insulation and Jacketing  DOE Compliant  Firing Rate Potentiometer  5-Year Warranty  Freight to Jobsite NOT INCLUDED: Labor Warranty, Boiler and Boiler Trim Assembly, BAS Control System, Vent Materials, Startup, EPO Switches Net Price per Boiler $33,969.00 Add price for factory authorized boiler startup - $ 500 per boiler Your building technology partner, LONG Building Environments Archie Warthen 5001 S Zuni Street Littleton, CO 80120 303.975.2158 tel 303.936.2755 fax awarthen@long.com www.long.com G:\LONG Hydronics\Jobs\Edora Pool Ice Center\4 - Proposals\BOILER QUOTE - EPIC Boiler Replacement 6.2.16.doc Colorado Nevada Utah Wyoming Technology for Better Buildings…Since 1965 TERMS AND CONDITIONS OF SALE - EQUIPMENT & PARTS 1. OFFER AND ACCEPTANCE: LONG BUILDING ENVIRONMENTS (LONG) is a manufacturer's agent representing the various suppliers quoted in this proposal. Acceptance of this proposal is deemed to be acceptance of the terms and conditions set forth by the various suppliers represented herein. All orders accepted by LONG and its suppliers are with the express condition that the purchaser agrees with the terms and conditions appearing in this proposal. LONG and its suppliers failure to object to the provisions contained in the Buyer's purchase order or other communications shall not be deemed a waiver of the terms and conditions hereof or acceptance of such provisions. No representations or guarantees other than those contained herein shall be binding upon LONG and its suppliers unless made in writing and signed by an Officer of LONG and its suppliers 2. PRICE POLICY: Quotations are subject to acceptance within fifteen (15) days from the date of quotation. 3. TAXES: Taxes are not included in the prices quoted on this proposal. The amount of any present or future taxes applicable to the product shall be added to the price contained herein and paid by the Buyer in the same manner and with the same effect as if originally added thereto. 4. INSTALLATION: This proposal does not include installation labor, supplies or rigging unless otherwise noted in the proposal. 5. PRODUCT CHANGES: In the interest of continuous product improvement, LONG and its suppliers reserve the right to change specifications and/or design without incurring obligation. 6. TERMS: Terms of payment are “Net 30 days” and are subject at all times to the approval of LONG and its suppliers' Credit Departments. LONG reserves the right to charge interest in the amount of one and one-half percent (1 ½%) per month on any outstanding balance. 7. DELIVERY: Supplier shipment dates are an approximation and shall not be binding on LONG or its suppliers unless specifically agreed to in writing by an officer of LONG. Shipment shall be F.O.B. Factory with title passing to Buyer upon delivery to the carrier by LONG or its suppliers. 8. CLAIMS: The responsibility of LONG and their suppliers ceases upon delivery of goods in good order to the carrier. Claims for factory shortages will not be considered unless made in writing to LONG within ten (10) days after receipt of the goods and accompanied by reference to our bill of lading and factory order numbers. As all goods are shipped at Buyer's risk, damage must be so noted on signed delivery receipt and any claims for damage or shortage in transit must be filed by Buyer against the transportation company. 9. CANCELLATION: LONG reserves the right to collect cancellation charges including, but not limited to all costs, expenses and reasonable overhead and profit. 10. DELAYS: LONG and its suppliers shall not be liable for any delays caused by riots, strikes, fires, floods, lack of transportation, accidents or due to disapproval of credit by LONG or its suppliers, or any other contingency beyond its control. In the event of disapproval of credit, LONG may, at its sole option, cancel Buyer’s Purchase Order without any liability on the part of LONG or its suppliers. 11. O&M DATA: LONG shall deliver operation and maintenance data after delivery of product, provided Buyer is current with its financial obligations to LONG. 12. RETURNED GOODS: Goods may not be returned except by permission of an authorized Officer of LONG and when so returned will be subject to a handling charge and transportation costs. Authorized return goods should be returned to suppliers as directed by LONG depending on point of origin. Return shipments should not be directed to LONG. 13. WARRANTY: LONG and its suppliers warrant to the original purchaser that the products manufactured or supplied by them are free of defects in material and workmanship if properly installed, maintained and used under normal conditions with competent supervision. The obligation of LONG and its suppliers is limited to, at their option, repairing or replacing, F.O.B. point of manufacture or main office of LONG, any part or parts under this warranty which shall thus prove defective within one year after shipment to the original purchaser (some suppliers may extend the warranty to one year after startup, or eighteen months after shipment, whichever occurs first). LONG and suppliers' examination shall disclose to their satisfaction the warranty status of parts claimed to be thus defective; warranty shall be valid provided such part or parts are returned to the supplier's manufacturing point or LONG main office with transportation charges prepaid and provided that LONG and its suppliers receive written notice of such defect within 15 days of the failure of the product and provided product has been paid in full. The term "original purchaser", as used in this warranty shall mean that person to whom the product was originally supplied. This warranty shall not apply to, and neither LONG nor its suppliers shall be liable for, any part which has been damaged by or subjected to misuse, abuse, overload, misapplication neglect, accident, improper installation, modification, adjustment, alteration or repair. This warranty is expressly in lieu of all other warranties, express or implied, including all warranties of merchantability and fitness for purpose or use and of all other obligations or liabilities of LONG or its suppliers; LONG and its suppliers neither assume nor authorize any other person to give or assume for them any other warranty or liability in connection with these products. 14. LIMITATION OF LIABILITY: LONG and its suppliers shall not in any event be liable for loss, damage or expense directly or indirectly arising from the use of said products nor from any other cause, nor for penalties, nor for indirect, special, consequential, incidental or liquidated damages and neither LONG nor its suppliers shall incur any liability whatsoever until full payment for products has been received. In no event shall LONG’s liability for direct or compensatory damages exceed the payments received by LONG from Buyer under Purchase Order. *131262433* QUOTE # BILL TO SHIP TO THE PRICES BELOW ARE VALID FOR 10 DAYS AND WILL BE SUBJECT TO CHANGE IF THE SUPPLIER CHANGES OUR COST. DATE P.O. # SHIP VIA SMAN TERMS ITEM/MFG# DESCRIPTION QTY UOM PRICE TOTAL SID HARVEY INDUSTRIES, INC. **QUOTATION** 300 LINCOLN CT. FORT COLLINS, CO 80524 PAGE 1 PHONE: (970) 221-1929 FAX #: (970) 493-0747 131262433 0059989 CITY OF FT COLLINS ACCOUNTING P, O BOX 580 FORT COLLINS CO 80522 PHONE: (970) 221-6770 CITY OF FT COLLINS ACCOUNTING P, O BOX 580 FORT COLLINS CO 80522 PHONE: (970) 221-6770 6/06/16 QUOTE ONLY PICK 1311 NET 10TH GDD BG-1394-W boiler,water,3,480mbh,na 1 EA 65,253.7500 65,253.75 BG-1394-W IF THIS ORDER IS SHIPPED, THEN APPLICABLE SHIPPING WILL BE CHARGED SUB TOTAL 65,253.75 FREIGHT 450.00 TOTAL.... 65,703.75 -00 FAX #: (000) FAX #: (000) Part Number 550-110-330/0598 Power-Flame burner model WCR Flame retention burner for gas, light oil and combination gas/light oil firing Burner Specification 94 and Data Sheet Model WCR Note: Add .38 to “H” dim for size of opening in boiler front plate. A S I 5/8 Dia., 4 holes E 4.00 F H G 3.13 X X D B(R) C(R) CL CL CL Dimensions in Inches Burner Model Number ABCDEF*GHISW WCR3 44.00 7.00 15.25 6.00 16.00 22.38 5.00 10.13 11.50 15.50 10.00 WCR4 50.00 7.31 17.69 7.00 18.50 28.00 5.00 12.13 14.25 19.13 12.00 WCR5 50.00 7.31 17.69 7.00 18.50 26.50 5.00 12.13 14.25 19.13 12.00 * Required for installation of standard control components. Part Number 550-110-330/0598 Power-Flame Model WCR 2 1 2 3 4 5 6 7 Notes Burner capacities listed for elevations up to 2,000 feet. For higher elevations, consult local Weil-McLain distributor/agent or sales office. Light oil ratings based on No. 2 fuel oil with heating value of 140,000 Btu per gallon. Gas ratings based on natural gas with heating value of 1,000 Btu per cubic foot and specific gravity of 0.60. Gas burners for other gases are available. Consult local Weil-McLain distributor/agent or sales office. Boiler-burner unit to be adjusted to achieve +0.10 inches W.C. pressure at the flue collar, resulting in positive pressure in firebox as listed. Minimum gas pressures listed are subject to variations due to job conditions. Gas burners for other gas pressures are available. Consult local Weil-McLain distributor/agent or sales office. Manifold pressures and combustion air settings shown are for initial start-up. Final pressure and air settings should be determined after checking actual gas flow and combustion readings. Gas Control Systems • LHO: On-off operation, low fire start, high fire run. 894-1394 – two-position air controlled by damper arm on motorized gas valve, fixed damper pre-purge. 1494-1894 – two-position air controlled by separate motor, open damper pre-purge. • LHL: Low-high-low-off firing conditions. 894-1394 – two-position air controlled by damper arm on motorized gas valve, fixed damper pre-purge. 1494-1894 – two-position air controlled by separate motor, open damper pre-purge. • MOD: On-off operation, with proven low fire start and full modulating firing conditions with combustion air control. Proportional motor drives fuel metering valve and combustion air damper according to the firing conditions. Open damper pre-purge. No. 2 Oil GPH Gas MBH Gas Light Oil Gas/Light Oil Gas Light Oil Gas/Light Oil Gas Light Oil Gas/Light Oil Gas Light Oil Gas/Light Oil 894 17.60 2540 0.27 WCR3-G-20 WCR3-O WCR3-GO-20 RM7895C R8184G RM7896C LHO LHO LHO/LHO 1 1/2 2 2 Three Phase* 994 20.00 2887 0.31 WCR3-G-20 WCR3-O WCR3-GO-20 RM7895C R8184G RM7896C LHO LHO LHO/LHO 1 1/2 2 2 Three Phase* 1094 22.50 3247 0.35 WCR3-G-20 WCR3-O WCR3-GO-20 RM7895C RM7896A RM7896C LHO LHO LHO/LHO 1 1/2 2 2 Three Phase* 1194 25.00 3608 0.39 WCR3-G-20 WCR3-O WCR3-GO-20 RM7895C RM7896A RM7896C LHO LHO LHO/LHO 1 1/2 2 2 Three Phase* 1294 27.50 3969 0.43 WCR3-G-25 WCR3-O WCR3-GO-25 RM7895C RM7840L RM7896C LHO LHO LHO/LHO 1 1/2 2 2 Three Phase* 1394 30.00 4330 0.47 WCR3-G-25 WCR3-O WCR3-GO-25 RM7895C RM7840L RM7840L LHO LHO LHO/LHO 1 1/2 2 2 Three Phase* 1494 32.50 4691 0.51 WCR4-G-25 WCR4-OA WCR4-GO-25 RM7840L RM7840L RM7840L LHO LHO LHO/LHO 3 5 5 Three Phase* 1594 35.00 5052 0.55 WCR4-G-25 WCR4-OA WCR4-GO-25 RM7840L RM7840L RM7840L LHO LHO LHO/LHO 3 5 5 Three Phase* 1694 37.50 5412 0.58 WCR4-G-25 WCR4-OA WCR4-GO-25 RM7840L RM7840L RM7840L LHO LHO LHO/LHO 3 5 5 Three Phase* 1794 40.00 5773 0.62 WCR4-G-25 WCR4-OA WCR4-GO-25 RM7840L RM7840L RM7840L LHO LHO LHO/LHO 3 5 5 Three Phase* 1894 42.50 6134 0.66 WCR4-G-25 WCR4-OA WCR4-GO-25 RM7840L RM7840L RM7840L LHO LHO LHO/LHO 5 5 5 Three Phase* 1994 45.00 6495 0.70 WCR4-G-30 WCR4-OB WCR4-GO-30 RM7840L RM7840L RM7840L MOD MOD MOD/MOD 5 5 5 Three Phase* 2094 47.50 6856 0.75 WCR4-G-30 WCR4-OB WCR4-GO-30 RM7840L RM7840L RM7840L MOD MOD MOD/MOD 5 5 5 Three Phase* 2194 50.00 7216 0.85 WCR5-G-30 WCR5-O WCR5-GO-30 RM7840L RM7840L RM7840L MOD MOD MOD/MOD 5 5 5 Three Phase* 2294 53.00 7649 0.95 WCR5-G-30 WCR5-O WCR5-GO-30 RM7840L RM7840L RM7840L MOD MOD MOD/MOD 5 5 5 Three Phase* 2394 55.00 7938 1.05 WCR5-G-30 WCR5-O WCR5-GO-30 RM7840L RM7840L RM7840L MOD MOD MOD/MOD 7 1/2 7 1/2 7 1/2 Three Phase* 2494 58.00 8371 1.15 WCR5-G-30 WCR5-O WCR5-GO-30 RM7840L RM7840L RM7840L MOD MOD MOD/MOD 7 1/2 7 1/2 7 1/2 Three Phase* 2594 60.00 8660 1.25 WCR5-G-30 WCR5-O WCR5-GO-30 RM7840L RM7840L RM7840L MOD MOD MOD/MOD 7 1/2 7 1/2 7 1/2 Three Phase* * 208/60/3, 240/60/3, 480/60/3 burner motor voltage must be specified. Standard Motor Voltage Standard Burner Model Designation 3 Burner Specification and Data Sheet Part Number 550-110-330/0598 Notes Light Oil Control Systems: • LHO: On-off operation, low fire start, high fire run. Two-position air, two-position oil. Fixed damper pre-purge on 894-1194, open damper pre-purge on 1294-1894. • LHL: Low-high-low-off firing conditions. Two-position air, two-position oil. Fixed damper pre-purge on 894-1194, open damper pre-purge on 1294-1894. • MOD: On-off operation, with proven low fire start and full modulating firing conditions. Proportional motor drives fuel metering valve and combustion air damper according to the firing conditions. Open damper pre-purge. Gas/Light Oil Control Systems: • LHO/LHO: Combines gas and light oil characteristics listed above. • LHL/LHL: Combines gas and light oil characteristics listed above. • MOD/MOD: Combines gas and light oil characteristics listed above. 120/60/1 control circuit is used for all burners. Control circuit transformer is available as an option. Motor starter or contactor will be furnished for all burners. Combustion Controls: a) R8184G combustion control uses cadmium cell for flame detector to monitor oil burner flame, also furnishes intermittent ignition. b) RM7895 flame safeguard control uses ultraviolet electronic flame detector to monitor gas or oil burner flame and provides pre-purge programming. “A” models provide intermittent pilot; “C” models provide interrupted pilot and RUN/TEST switch. RM7896 provides same as above with post-purge. c) RM7840L, E110/EPD170 flame safeguard control monitors the oil or gas burner flame, provides pre-purge and post-purge programming, provides switching necessary to allow firing rate motor to be driven to both low fire and high fire positions, prevents start-up if pre-ignition interlocks are open and has low fire start proving circuit. In the event pre-ignition interlock circuit or running interlock circuit does not “prove”, system will lock out on safety. Control is standard equipment with IRI – modulating (proven low fire start) system. Ultraviolet sensitive electronic flame detector is standard with infrared detector available. d) RM7800L, E110/EP170 flame safeguard control monitors the oil or gas burner flame with digital readout control system, provides pre-purge and post-purge programming, provides switching necessary to allow firing rate motor to be driven to both low fire and high fire position, prevents start-up if pre-ignition interlocks are open and has low fire start proving circuit. In the event pre-ignition interlock circuit or running interlock circuit does not “prove”, system will lock out on safety. Ultraviolet sensitive electronic flame detector is standard with infrared detector available. 8 9 10 11 12 13 Minimum Maximum Top Bottom High Fire Low Fire 894 2.11 1.62 3.73 14.00 3/8 3/8 12.00 Monarch BPS 80 o 300 240 185 80-170 22R322D 105 Direct 3450 -- 994 2.77 2.08 4.85 14.00 3/8 3/8 13.50 Monarch BPS 80 o 300 241 176 80-125 22R322D 105 Direct 3450 -- 1094 3.50 2.55 6.05 14.00 3/8 3/8 13.50 Monarch BPS 80 o 300 291 210 80-140 22R322D 105 Direct 3450 -- 1194 4.30 3.03 7.33 14.00 3/8 3/8 17.50 Monarch BPS 80 o 300 236 160 80-135 22R322D 105 Direct 3450 -- 1294 4.36 3.71 8.07 14.00 3/8 3/8 17.50 Monarch BPS 80 o 300 275 185 80-145 22R322D 105 Direct 3450 -- 1394 5.19 4.29 9.48 28.00 3/8 3/8 19.50 Monarch BPS 80 o 300 288 204 60-110 22R322D 105 Direct 3450 -- 1494 6.08 2.10 8.18 28.00 3/8 3/8 21.50 Monarch BPS 80 o 300 274 221 60-100 22R323D 135 Direct 3450 -- 1594 7.05 2.35 9.40 28.00 3/8 3/8 24.00 Monarch BPS 80 4 Part Number 550-110-330/0598 Weil-McLain 500 Blaine Street Michigan City, IN 46360-2388 http://www.weil-mclain.com Power-Flame Model WCR Flame safeguards provided with listed control systems by code Notes Airflow safety switch is standard for all gas and combination gas/light oil units. Burners will be completely assembled and wired (except gas train) and factory test-fired. Burners listed by Underwriters Laboratories, Inc., state of Connecticut, Fire Marshal state of Massachusetts, city of New York MEA, and others. Special controls can be provided to meet other code requirements not listed. Consult your local Weil-McLain distributor/agent or sales office. Direct spark ignition is standard on light oil units 894-1794. Electric-gas pilot is standard on gas and combination gas/light oil units and on light oil units 1894-2594. Direct spark ignition is optional on combination gas/light oil units. Consult your local Weil-McLain distributor/agent or sales office. 14 15 16 17 18 Gas/light oil LHO LHL MOD LHO LHL MOD LHO LHL MOD LHO LHL MOD 894-1194 RM7896C RM7896C RM7840L RM7896C RM7896C RM7840L RM7896C RM7896C RM7840L RM7896C RM7896C RM7840L 1294-1894 RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L 1994-2594 -- -- RM7840L -- -- RM7840L -- -- RM7840L -- -- RM7840L Boiler - Part No. 550-110-275/0810 for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners This manual must only be used by a qualiﬁed heating installer/service technician. Read all instructions before installing. Follow all in- structions in proper order. Failure to comply could result in severe personal injury, death or substantial property damage. When calling or writing about the boiler— Please have the boiler model number (and series) from the boiler rating label and the CP number from the boiler jacket. INSTALLER Consider piping and installation when determining boiler location. Any claims for damage or shortage in shipment must be ﬁled immediately against the transportation company by the consignee. USER . . . . This manual is for use only by your qualiﬁed heating installer/service technician. Boiler and burner must be installed by a qualiﬁed service technician. We recom- mend regular service by a qualiﬁed service technician, at least annually. For additional information, refer to . . Burner speciﬁcation and data sheets (for burners pre-tested with model 94 boilers) s )NSTALLATION s 3TARTUP s -AINTENANCE Boilers 0ARTS Manual Water & steam boilers 94 Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 2 Part No. 550-110-275/0810 Hazard Deﬁnitions The terms deﬁned below 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 if ignored. Indicates presence of hazards that CAN CAUSE SEVERE personal injury, death or substantial property damage if ignored. Indicates presence of hazards that WILL OR CAN CAUSE MINOR personal injury, death or substantial property damage if ignored. Indicates special instructions on installa- tion, operation or maintenance that are im- portant but not related to personal injury. Controls: /NE LIMIT CONTROL is supplied with the boiler. A second limit control must be supplied by the installer (ﬁeld installed) to comply with current ASME Boiler and Pressure Vessel Code, Section IV. IMPORTANT When calling or writing about the boiler, please provide: s "OILER MODEL NUMBER s 3ERIES s #0 NUMBER This information is located on the boiler label/nameplate. Read before proceeding: Read all instructions before installing. Fail- ure to follow all instructions in proper order can cause severe personal injury, death or substantial property damage. Do not use petroleum-based cleaning or sealing components in boiler system. Severe damage to system components can result, causing substantial property damage. 0ROPANE BOILERS ONLY — Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade and the gas may no longer have an odor. N Propane gas can accumulate at ﬂoor level. Smell near the ﬂoor for the gas odorant or any unusual odor. If you suspect a leak, do not attempt to light the burner. N Use caution when attempting to light a propane burner (or pilot burner). This should be done by a qualiﬁed service technician, particularly if ﬂame out- ages (or pilot outages) are common. N Periodically check the odorant level of your gas. N Inspect boiler and system at least yearly to make sure all gas piping is leak- tight. "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 3 Contents "EFORE INSTALLING BOILER 4 3ET BOILER IN PLACE 7 !SSEMBLING THE BLOCK 8 0ERFORM HYDROSTATIC PRESSURE TEST 11 #ONTROL TAPPING LOCATIONS WATER BOILERS 12 #ONTROL TAPPING LOCATIONS STEAM BOILERS 13 #ONNECT WATER BOILER PIPING 14 #ONNECT STEAM BOILER PIPING 16 #OMPLETE BLOCK ASSEMBLY INSTALL JACKET 20 0IPE TANKLESS HEATERS 25 )NSTALL WATER BOILER CONTROLS 26 )NSTALL STEAM BOILER CONTROLS 28 #ONNECT BREECHING AND VENTING SYSTEMS 31 #ONNECT BREECHING AND VENTING SYSTEMS 32 )NSTALL FUEL PIPING 34 -AKE lNAL ADJUSTMENTS 35 (ANDLING CERAMIC lBER AND lBERGLASS MATERIALS 36 -AINTENANCE AND TROUBLESHOOTING 37 2ATINGS 41 $IMENSIONS 42 0ARTS 44 Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 4 Part No. 550-110-275/0810 Installation must comply with — 1. State, provincial and local plumbing, heating and electrical codes. 2. Regulations of servicing utilities. 3. ASME Section IV, Low Pressure Boiler and Pressure Vessel Code. 4. National Fuel Gas Code, ANSI/NFPA 54, when applicable. 5. National codes where applicable. Before selecting boiler location 1. Check for nearby connections to: a. Fuel supply. b. Electrical power. c. System water or steam piping. d. Venting systems — see page 31. e. Combustion and ventilation air supply — see page 5. 2. Check area around boiler. Remove any combustible materials, gasoline and other ﬂammable vapors and liquids. Failure to keep boiler area clear and free of combustible materials, gasoline and other ﬂammable liquids and vapors can result in severe personal injury, death and substantial property damage. Provide clearance around boiler 1. Provide minimum CLEARANCES TO COMBUSTIBLE MATERIALS: s "OILER TOP — 24 inches. s "OILER FRONT — 48 inches. s "OILER mUE — 9 inches. s "OILER REAR — 9 inches. s "OILER SIDES — 6 inches. s 3INGLE WALL VENT PIPE – 18 inches. s $OUBLE WALL VENT PIPE – refer to vent pipe manufacturer's recom- mendations for vent pipe clearances. 2. Boiler may be installed on combustible ﬂooring. 3. See page 42 for boiler dimensions. Flue pipe/breeching clearances take precedence over jacket clearances. Follow local codes requirements for clearances. Increase clearances if necessary. 4. Provide minimum CLEARANCES FOR SERVICING: s 2IGHT SIDE — for cleaning and for tankless heater insertion/re- moval — 44 inches. s 2EAR — for breeching — 50 inches. s Allow sufﬁcient space on remaining sides for cleaning, servicing and burner installation. See burner literature for length and recom- mended service clearances. Lay a foundation, if needed 1. Floor construction and condition must be suitable for weight of boiler when ﬁlled with water. See page 42 for approximate boiler operating weight. 2. A level concrete or brick foundation, constructed per Figure 1 and Figure 2 is required when: a. A ﬂoor could possibly become ﬂooded. b. Non-level conditions exist. c. Boiler must be raised for burner clearance. Before installing boiler &IGURE Boiler foundation, when required — always use steel strips as shown for proper draw-up and alignment of sections &IGURE Boiler foundation (see Figure 1) "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 5 Before installing boiler (continued) Combustion and ventilation air openings Adequate combustion and ventilation air must be provided to assure proper combustion and prevent possibility of ﬂue gas leakage and carbon monoxide emissions, causing severe personal injury or death. Do not install an exhaust fan in boiler room. Incor- rect burner operation can result. When combustion and ventilation air enters through side wall openings, ensure that the open- ings comply with the requirements of Figure 3 and Figure 4. Opening sizes must comply with state, provincial or local codes. In the absence of local requirements, use the National Fuel Gas Code, ANSI/NFPA 54). The following information is taken from ANSI/NFPA 54. For details and information not addressed below, refer to the standard. Combustion air openings to inside 2EQUIRED VOLUME OF INTERIOR SPACES ANSI/NFPA 54 allows combustion air to be supplied through openings to interior spaces IF THE VOLUME OF THE CONNECTED INTERIOR SPACES MEETS THE MINIMUM VOLUME REQUIRED BY THE STANDARD. The minimum volume of interior spaces can be taken as 50 cubic feet per 1,000 Btuh of all appliances in the spaces, or the minimum volume can be calculated using the formulas given in ANSI/NFPA 54. Excep- tion: If the air inﬁltration rate for the spaces is known to be less than 0.40 air changes per hour, the minimum volume must be calculated as speciﬁed in the standard. )NSIDE AIR OPENING SIZES AND LOCATIONS For spaces that provide the minimum volume required by ANSI/ NFPA 54, the air openings must be sized per the following: #OMBINING SPACES ON THE SAME STORY Each opening shall have a minimum free area of 1 in2 ⁄1000 Btuh (2200 mm2 /kW) of the total input rating of all appliances in the space but not less than 100 in2 (0.06 m2). One opening shall commence within 12 inches (300 mm) of the top, and one opening shall commence within 12 inches (300 mm) of the bottom, of the enclosure. The minimum dimension of air openings shall be not less than 3 inches (80 mm). #OMBINING SPACES IN DIFFERENT STORIES The volumes of spaces in different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or ﬂoors having a total minimum free area of 2 in2 ⁄1000 Btuh (4400 mm2 /kW) of total input rating of all appliances. &IGURE Combustion and ventilation air openings — Boiler room below grade &IGURE Combustion and ventilation air openings — Boiler room partially or completely above grade Combustion air openings to outside Outdoor combustion air can be taken through per- manent openings (TWO or ONE), as described in the following. The minimum dimension of air openings shall not be less than 3 inches (80 mm). Outside openings TWO PERMANENT OPENINGS METHOD Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 6 Part No. 550-110-275/0810 Before installing boiler (continued) freely communicate with the outdoors, as follows: s Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in2 ⁄4000 Btuh (550 mm2/kW) of total input rating of all appliances in the enclosure. s Where communicating with the outdoors through hori- zontal ducts, each opening shall have a minimum free area of 1 in2 ⁄2000Btuh (1100 mm2 /kW) of total input rating of all appliances in the enclosure. Outside openings ONE PERMANENT OPENING METHOD One permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided. The appliance shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following: (1) 1 in2 ⁄3000 Btu/hr (700 mm2 per kW) of the total input rating of all appliances located in the enclosure, and . . . (2) Not less than the sum of the areas of all vent connectors in the space. Combustion air — combination indoor and outdoor openings ANSI/NFPA 54 allows combustion air to be taken from a com- bination of openings to outside and to interior spaces. Follow all requirements of the standard to determine the minimum volume of interior spaces and to calculate minimum sizes of openings. Engineered Installations Engineered combustion air installations shall provide an ad- equate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction. Mechanical Combustion Air Supply Where all combustion air is provided by a mechanical air supply system, the combustion air shall be supplied from outdoors at the minimum rate of 0.35 ft3/minute per 1000 Btuh (0.034 m3/ min per kW) for all appliances located within the space. s Where exhaust fans are installed in the building, addi- tional air shall be provided to replace the exhausted air. s Each of the appliances served shall be interlocked to the mechanical air supply system to prevent main burner operation where the mechanical air supply system is not in operation. s Where combustion air is provided by the building’s me- chanical ventilation system, the system shall provide the speciﬁed combustion air rate in addition to the required ventilation air. Louvers, Grilles, and Screens. The required size of openings for combustion, ventilation, and di- lution air shall be based on the NET FREE AREA of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size opening required to provide the free area speciﬁed. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25 percent free area, and metal louvers and grilles will have 75 percent free area. "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 7 Set boiler in place Do not raise or move assembled sections using a jack or forklift. This could cause the sections to shift, resulting in leaks. &IGURE Section assembly lifting weights "OILER MODEL NUMBER !PPROXIMATE LIFTING WEIGHT (pounds) -INIMUM SLING LENGTH (from crane hook to boiler lifting lugs) 894 8600 3' 6" 994 9500 3' 6" 1094 10300 4' 0" 1194 11200 4' 6" 1294 12000 5' 0" 1394 12800 5' 0" 1494 13700 5' 0" 1594 14500 5' 0" 1694 15400 5' 0" 1794 16200 5' 0" 1894 17100 5' 0" 1994 17900 5' 6" 2094 18700 5' 6" 2194 19800 7' 6" 2294 20600 7' 6" 2394 21500 7' 6" 2494 22400 8' 0" 2594 23200 8' 0" Ensure the equipment and cables used for lifting are designed to handle the load. See Figure 5 for approximate weights of model 94 section assemblies. Failure to comply can result in severe personal injury, death or substantial property damage. The boiler contains ceramic ﬁber and ﬁberglass materials. Use care when handling these materials per instructions on "Handling ceramic ﬁber and ﬁberglass materials," page 36 of this manual. Failure to comply could result in severe personal injury. For packaged boiler or assembled block assembly: 1. Packaged boilers only — Remove top jacket panels. Set aside until after boiler is piped. 2. Remove lag screws from shipping rails. 3. Remove boiler from skid. Cables are already attached to block as- sembly. See Figure 5 for lifting weight. s Using crane – attach free end of cables to eye of crane. s Using hoist – attach free end of cables to hoist. Raise boiler off skid. Use pipe rollers under steel skid angles to roll boiler. 4. Place ¼" x 3" steel plates on ﬂoor or foundation, spaced 51 inches apart, as shown in Figure 1, page 4. 5. Place boiler in ﬁnal position. Place boiler on foundation (if used) Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 8 Part No. 550-110-275/0810 Assembling the block Sections are top heavy. Unbolted sections may fall if not supported, resulting in severe personal injury or death. Prepare the back section ﬁrst 1. Place ¼" x 3" steel plates on the ﬂoor or foundation, spaced 51 inches apart, as shown in Figure 1, page 4. 2. Apply 1⁄8" continuous bead of sealing rope adhesive in sealing rope grooves around section perimeter and around ﬂueways — see Fig- ure 6. $O NOT GET ANY ADHESIVE ON THE MACHINED PORT SUR FACES. Place sealing rope in grooves 1. Place 5⁄8" coated and uncoated sealing rope in the rope grooves as shown in Figure 6. 2. See WARNING below — place coated rope and uncoated rope as described. 3. Around curves, grasp rope at 1" intervals and push together. $O NOT STRETCH THE ROPE. The boiler is supplied with TWO types of section sealing rope — uncoated and coated with a narrow uncoated strip. Use the uncoated rope only on the ﬂueways as shown in Figure 6. Use the coated rope around the perimeter and around the upper nipple port as shown in Figure 6. The uncoated side of the rope must be pressed into the adhesive as shown in order to obtain a proper adhesion. DO NOT pre-cut rope for sections. Cut rope as each sec- tion is placed. A gas-tight seal must be maintained to prevent possibility of ﬂue gas leakage and carbon monoxide emissions, caus- ing severe personal injury or death. Do not use petroleum-based cleaning or sealing com- pounds in boiler system. Severe damage to system compo- nents can result, causing substantial property damage. Install nipple port sealing rings 1. Remove any grit from port machined surfaces with clean rag. 2. Place 9" and 6" sealing rings in appropriate port openings as shown in Figure 6, page 8. If sealing ring slips out of groove, stretch ring gently for several seconds, then reposition in groove. 3. Apply a continuous bead of silicone sealant no larger than 1⁄16" around entire outside edge of the OUTER machined surface of the port. See Figure 7. $O NOT APPLY SILICONE SEALANT ON "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 9 Assembling the block (continued) &IGURE Applying silicone sealant around outsides of sealing rings (shown on 94 intermediate section upper nipple port) &IGURE Sealing ring installation and port alignment, typical Weil- McLain cast iron section nipple port Silicone sealant applied as speciﬁed above prevents unburned oil vapors from coming in contact with sealing ring. Vapor con- tact can damage rings, resulting in severe damage to boiler and substantial property damage. Raise the rear section upright 1. Hoist the back section upright. 2. Move rear section into position on the steel rails. The section should be 4 inches from the end of the founda- tion (if used) as shown in Figure 1, page 4. 3. Block under the the ﬂueway outlet to hold the rear sec- tion upright in plumb position. The back section must be plumb before in- stalling other sections to ensure the block will assemble correctly. 4. The blocking under the ﬂueway can be removed later, after several intermediate sections have been attached and the assembly is stable. 5. Install intermediate sections and front section as de- scribed on the following. Install intermediate sections 1. Remove and discard 3⁄8" diameter shipping tie rods. 2. Remove grit from port machined surfaces with clean rag. Also remove grit from tapped holes in all sections. Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to system components can result, causing substantial property damage. 3. Position intermediate section so aligning lugs ﬁt into sockets of next section. See Figure 8. 4. Draw sections together until metal-to-metal contact is made around machined port openings (see Figure 8): a. Oil threads on (4) 5⁄8" x 11" draw rods. Install washer and nut on end to be tightened. Use nut only on other end. b. Uniformly draw sections together, starting at washer/nut end. Important — Leave an equal amount of thread on each end of the draw rod. This is needed to allow securing the jacket support brackets in place. The draw rods must not extend past the face of the front or back section, or they will interfere with the jacket. c. Draw rods should be torqued to a range of 100 to 120 ft-lbs. Do not back off draw rods. d. Metal-to-metal contact will be achieved around port openings. See Figure 8. If gap occurs, it should be no greater than .032". Check with feeler gauge. Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 10 Part No. 550-110-275/0810 &IGURE Section arrangement (location of TI and SI sections, numbered from REAR to FRONT of block assembly) "OILER W = water S = steam 0LACEMENT OF SPECIAL INTERMEDIATE SECTIONS 4) AND 3) [numbering from REAR to FRONT, beginning with rear section as section number 1] TI SECTIONS with tankless coil openings SI SECTIONS with supply # of coils ——> 12 3 4 5 6 7 8 tappings 894 W or S 5 5, 7 3, 5, 7 — — — — — — 994 W or S 6 6, 8 2, 4, 6 2, 4, 6, 8 — — — — — 1094 W or S 4 2, 4 2, 4, 7 2, 4, 7, 9 — — — — — 1194 W or S 4 2, 4 2, 4, 8 2, 4, 8, 10 — — — — — 1294 W or S 4 2, 4 2, 4, 9 2, 4, 9, 11 2, 4, 7, 9, 11 — — — — 1394 W or S 5 3, 5 3, 5, 10 3, 5, 10, 12 3, 5, 8, 10, 12 — — — — 1494 W or S 6 4, 6 2, 4, 6 4, 6, 11, 13 2, 4, 6, 11, 13 2, 4, 6, 9, 11, 13 — — — 1594 W or S 6 4, 6 2, 4, 6 4, 6, 12, 14 2, 4, 6, 12, 14 2, 4, 6, 10, 12, 14 — — — 1694 W or S 6 4, 6 2, 4, 6 4, 6, 13, 15 2, 4, 6, 13, 15 2, 4, 6, 9, 11, 13 2, 4, 6, 9, 11, 13, 15 — — 1794 W or S 7 5, 7 3, 5, 7 5, 7, 14, 16 3, 5, 7, 14, 16 3, 5, 7, 10, 12, 14 3, 5, 7, 10, 12, 14, 16 — — 1894 W or S 8 6, 8 2, 4, 6 2, 4, 6, 8 2, 4, 6, 8, 15 2, 4, 6, 8, 15, 17 2, 4, 6, 8, 11, 13, 15 2, 4, 6, 8, 11, 13, 15, 17 — 1994 W or S 6 4, 6 2, 4, 6 4, 6, 9, 11 2, 4, 6, 9, 11 2, 4, 6, 9, 11, 16 2, 4, 6, 9, 11, 16, 18 2, 4, 6, 9, 11, 14, 16, 18 — 2094 W or S 6 4, 6 2, 4, 6 4, 6, 10, 12 2, 4, 6, 10, 12 2, 4, 6, 10, 12, 17 2, 4, 6, 10, 12, 17, 19 2, 4, 6, 10, 12, 15, 17, 19 — 2194 W 6 4, 6 2, 4, 6 2, 4, 6, 9 2, 4, 6, 9, 11 2, 4, 6, 9, 11, 13 2, 4, 6, 9, 11, 13, 16 — 18, 20 2294 W 6 4, 6 2, 4, 6 2, 4, 6, 10 2, 4, 6, 10, 12 2, 4, 6, 10, 12, 14 2, 4, 6, 10, 12, 14, 17 — 19, 21 2394 W 6 4, 6 2, 4, 6 2, 4, 6, 9 2, 4, 6, 9, 11 2, 4, 6, 9, 11, 13 2, 4, 6, 9, 11, 13, 15 2, 4, 6, 9, 11, 13, 15, 18 20, 22 2494 W 8 6, 8 2, 4, 6 2, 4, 6, 8 2, 4, 6, 8, 12 2, 4, 6, 8, 12, 14 2, 4, 6, 8, 12, 14, 16 2, 4, 6, 8, 12, 14, 16, 19 21, 23 2594 W 8 6, 8 2, 4, 6 2, 4, 6, 8 2, 4, 6, 8, 11 2, 4, 6, 8, 11, 13 2, 4, 6, 8, 11, 13, 15 2, 4, 6, 8, 11, 13, 15, 17 22, 24 2194 S 2 2, 9 2, 9, 11 2, 9, 11, 13 2, 9, 11, 13, 20 — — — 4, 6, 16, 18 2294 S 2 2, 10 2, 10, 12 2, 10, 12, 14 2, 10, 12, 14, 21 — — — 4, 6, 17, 19 2394 S 2 2, 9 2, 9, 11 2, 9, 11, 13 2, 9, 11, 13, 15 2, 9, 11, 13, 15, 22 — — 4, 6, 18, 20 2494 S 8 2, 8 2, 8, 12 2, 8, 12, 14 2, 8, 12, 14, 16 2, 8, 12, 14, 16, 23 — — 4, 6, 19, 21 2594 S 8 2, 8 2, 8, 11 2, 8, 11, 13 2, 8, 11, 13, 15 2, 8, 11, 13, 15, 17 2, 8, 11, 13, 15, 17, 24 — 4, 6, 20, 22 If the boiler was ordered with tankless coils, the heaters must be located on the right hand side of the boiler. It is important to position the TI sections (where used) in the exact location in the boiler section assembly as shown above so the heater knockout openings in the jacket side panels will accommodate the heaters. If the TI sections and internal water heaters are not positioned in the boiler section assembly as shown above, the installer must cut openings in the jacket side panels to accommodate the heaters. e. If, for any reason, the gap around machined port open- ing exceeds .032", check for rope extending from rope grooves, dirt on port openings or sockets, or misaligned lugs. If corrections are made and gap still exists, contact your Weil-McLain distributor or sales ofﬁce before con- tinuing installation. After erecting ﬁrst intermediate section, check both sections for plumb. Repeat the check as each additional section is installed. Failure to plumb sec- tions can cause misaligned piping and breeching, possibly resulting in property damage. 5. Repeat steps 1-5 for all remaining sections. NOTE — use 5⁄8" x 10" draw rods between intermediates. When used, install TI (tankless intermediate) and SI (supply intermediate) sections in the positions shown in Figure 9, page 10. 6. Check each section for proper sealing rope position before proceeding to next section. Failure to position sealing rope properly can cause boiler to not seal gas-tight. Gas tight seal prevents possible ﬂue gas leakage and carbon "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 11 Perform hydrostatic pressure test Install boiler connections 894 – 1294 W 1. Secure supply elbow and gasket to front section and supply outlet cover plate and gasket to back section. s Use 5⁄8" x 3" studs, nuts, and washers. s Thread ﬂat end of stud into section. 2. Secure 6" NPT return opening counterﬂange and gasket to back section using ¾" x 2" cap screws and washers. 1394 – 2094 W 1. Secure supply elbow and gasket to front section. 2. Secure supply outlet cover plate and gasket to back section. 3. Use 5⁄8" x 3" studs, nuts, and washers. 4. Thread ﬂat end of stud into section. 5. Secure 8" pipe with standard 8" ﬂange (not furnished) and gasket (furnished) to back section. Use ¾" x 2" cap screws and washers (furnished). 2194 — 2594 W 1. Secure outlet cover plate with 3 holes (¾" tapping on top) and gasket to front section. 2. Secure outlet cover plate with 2 holes and gasket to back section. 3. Use 5⁄8" x 3" studs, washers, and nuts. Thread ﬂat end of stud into section. 4. Secure 10" supply outlets and gaskets on top of "SI" sec- tions. s Supply outlet should have 1¼" tapping facing front. s Use 5⁄8" x 3" studs, nuts, and washers. 5. Secure 10" ﬂanged return adapter and gasket to back section using ¾" x 2" hex head cap screws and washers. 3 1. Secure supply elbow and outlet gasket to front section and supply outlet cover plate and gasket to back section. s Use 5⁄8" x 3" studs, nuts and washers. s Thread ﬂat end of stud into section. 2. Secure 6" return opening counter ﬂange and gasket to back section. Use ¾" x 2" cap screws and washers. 3 1. Secure supply elbows and outlet gaskets to front and back sections. s Use 5⁄8" x 3" studs, nuts and washers. s Thread ﬂat end of stud into section. 2. Secure 6" NPT return opening counterﬂange and gasket to back section. Use ¾" x 2" cap screws and washers. 3 1. Secure outlet cover plates and gaskets to front and back sections. s The ¾" tappings in plates should be at top. s Use 5⁄8" x 3" studs, nuts and washers. 2. Secure 10" supply outlets and gaskets on top of "SI" sec- tions. s Supply outlet installed close to boiler front should have 1¼" tapping facing front. s Use 5⁄8" x 3" studs, nuts, and washers. 3. Secure 6" NPT return opening counterﬂange and gasket to back section using ¾" x 2" hex head cap screws and wash- ers. Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 12 Part No. 550-110-275/0810 Control tapping locations — water boilers &IGURE Model 94 WATER boiler control tappings )TEM &UNCTION 3IZE (Inches NPT) J1 PRESSURE TEST GAUGE — REMOVE AFTER HYDROSTATIC TEST ½ J1 Temperature control or limit ½ * * PLUG these tappings — not used on water boilers ½ - Probe-type low water cutoff 1 - - Float-type low water cutoff or LWCO/feeder combination 1 - - 0 OR 2 Temperature control or limit 3 3 P/T gauge or temperature gauge ¾ 4 OR 4 Temperature control or limit — or — Air vent piping to compression tank 1¼ 5 5 Pressure relief valve(s): 894–2094: Install relief valve in one tapping and plug the other tapping 2194–2594: Install a relief valve in each tapping (2 relief valves required on these boilers) 2 V1 Temperature control or limit 4 7 OR 7 Temperature control or limit — or — P/T gauge or temperature gauge ¾ 8 OR 8 Temperature control or limit — or — Air vent piping to compression tank 1¼ 9 9 PLUG this tapping — unless needed for a control 3⁄8 : OR : Cleanout tappings — Front section — Install 3-inch close nipple and 3-inch cap in each cleanout tapping 3 : OR : Cleanout or drain tappings — Rear section — Install drain valve in one tapping; install 2½"x2" reducing nipple and 2" cap in the other 2½ Low limit control (when using tankless heaters) — locate in control tapping on one of the tankless heaters — Controls and ﬁttings must not obstruct cleanout openings or prevent required access to the boiler or components. "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 13 Control tapping locations — steam boilers &IGURE Model 94 STEAM boiler control tappings )TEM &UNCTION 3IZE (Inches NPT) J1 PRESSURE TEST GAUGE — REMOVE AFTER HYDROSTATIC TEST ½ * * Gauge glass ½ J2 PLUG this tapping — not used ½ - PLUG this tapping — not used 1 - - Float-type low water cutoff, LWCO/pump control or LWCO/feeder combination 1 - - 0 Skim tapping 3 0 Steam pressure relief valve 3 R1 Skim tapping 4 R2 Steam pressure relief valve 4 3 Steam pressure gauge — or — Pressure controls (limit, operating, etc.) ¾ 3 Pressure controls (limit, operating, etc.) ¾ 4 OR 4 Pressure controls (limit, operating, etc.) 1¼ 4 OR 4 Steam pressure gauge — or — Pressure controls (limit, operating, etc.) 1¼ 5 OR 5 Steam pressure relief valve — Install relief valve in one tapping and plug the other 2 6 OR 6 Steam pressure relief valve — or — Skim tapping 4 7 OR 7 Steam pressure gauge — or — Pressure controls (limit, operating, etc.) ¾ 7 OR 7 Pressure controls (limit, operating, etc.) ¾ 8 8 PLUG these tappings — not used 1¼ 8 8 PLUG these tappings — not used 1¼ 9 9 Try cocks 3⁄8 : OR : Cleanout tappings — Front section — Install 3-inch close nipple and 3-inch cap in each cleanout tapping 3 : OR : Cleanout or drain tappings — Rear section — Install drain valve in one tapping; install 2½"x2" reducing nipple and 2" cap in the other 2½ Low limit temperature control (when using tankless heaters) — locate in control tapping on one of the tankless heaters — Controls and ﬁttings must not obstruct cleanout openings or prevent required access to the boiler or components. Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 14 Part No. 550-110-275/0810 Connect water boiler piping General water piping information 1. System water supply and return piping should be installed and piping connections attached to boiler before erecting jacket or installing controls. 2. Do not pipe in through supply and out through return. This creates reverse water ﬂow through boiler that must not be used. 3. When installing in a system in which return water temperature can drop below 140°F, apply the by-pass piping with by-pass pump as shown in Figure 16, page 15. 4. When three-way valves are used for temperature modulation, install slow-opening valves to minimize the potential of boiler thermal shock. Install piping Install piping as shown in Figure 12, page 14 and Figure 16, page 15 (if applicable) for single boilers. For multiple boilers, see Fig- ure 17, page 15. Improperly piped systems or undersized piping can contribute to erratic boiler operation and possible boiler or system damage. 1. Connect supply and return piping: a. Size according to tables below. s For KNOWN mOW RATES OR HIGHER mOW RATE (less than 20°F temperature rise) through boiler, see Figure 13. s For UNKNOWN FLOW RATES, size piping per Figure 15, page page 15, using 20°F temperature rise through boiler. Flow at higher rates than shown in the tables in this manual for given pipe sizes can damage the boiler, caus- ing substantial property damage. b. Locate circulator in supply piping. c. For return piping, use full diameter pipe for 10 times that diameter before making any reduction. For example, a 4-inch return should not be reduced any closer to boiler return tap- ping than 40 inches. d. Install system blow-off (drain) valve in lowest part of return piping close to boiler. ASME minimum size requirements are given in Figure 15, page 15. 2. Install expansion tank: a. #LOSED TYPE – connect to 11⁄4" tapping T1, T2 or X2 (see Figure 10, page 12). Use 1" NPT piping. Any horizontal pip- ing must pitch up toward tank at least 1 inch per each 5 feet of piping. b. $IAPHRAGM TYPE – Refer to tank manufacturer's literature for location. Install automatic air vent in 11⁄4" tapping T1, T2 or X2 (see Figure 10, page 12). c. Connect cold water ﬁll to expansion tank piping. Figure 12 shows typical piping when using a closed type tank. Connect to the same location as the expansion tank connects to the system when using a diaphragm type tank. d. Also shown are recommended valves and water meter, when used. Water meter will detect added make-up water, indicating leaks in system. &IGURE Water boiler piping, typical &IGURE Recommended minimum pipe sizes for known ﬂow rates (note 1) 7ATER mOW RATE "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 15 Connect water boiler piping (continued) &IGURE Recommended minimum pipe sizes when ﬂow rate is not known (see Figure 12, page page 14) (note 1) "OILER MODEL 3UPPLY PIPE SIZE A 2ETURN PIPE SIZE B 894 5" 5" n 6" 6" n 8" 8" n 10" 10" Note 1 Pipe sizes are based on a 20°F temperature rise through the boiler. For applications with higher ﬂow rates (lower temperature rise), determine the ﬂow rate and use Figure 13, page page 14 to size the piping. DO NOT use ﬂow rates in excess of 520 GPM through 894–2094 or 820 GPM through 2194–2594. &IGURE ASME drain valve size "OILER MODEL -INIMUM DRAINBLOW OFF VALVE SIZE n 1¼" n 1½" n 2" Piping multiple boilers 1. See Figure 16. (Expansion tanks, relief valves and other accessories are required, but omitted from the illustration for simplicity.) 2. The boiler piping circuits are referred to as the secondary circuits in the following. 3. The legend for Figure 16 and boiler pump sizing recommenda- tions follow: A Size boiler pump GPM based on the following: A 4EMP RISE (IGH LIMIT TEMP n 2ETURN WATER TEMP B '0- "OILER 'ROSS /UTPUT Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 16 Part No. 550-110-275/0810 Connect steam boiler piping General steam piping information: 1. Hartford loop piping arrangement and wet return are required for steam boilers. Use the Hartford loop for both pumped-return and gravity-return systems. 2. Maintain 24-inch minimum from waterline to bottom of header (86 3⁄4" from bottom of section). 3. When using condensate receiver, feed pump must be energized by boiler-mounted pump controller. 4. Install piping: a. Install piping as shown on page 17 through page 18 for single boil- ers. See page 19 for additional requirements when piping multiple boilers. b. Return pipe sizing. s Pumped return — Size return piping by pump. s Gravity return — Size gravity return same as Hartford loop equalizer pipe size. c. Drain valve — Install system drain valve in lowest part of return piping close to boiler. See Figure 15, page 15, for sizing. d. Cold water ﬁll piping — Connect cold water ﬁll piping as shown in Figure 18. Also shown are recommended valves and water meter, if used. Water meter will detect added makeup water, indicating leaks in system. e. Condensate return piping: s Satisfactory operation of any steam heating system depends on adequate return of condensate to maintain steady water level. s Avoid adding excessive amounts of raw make-up water. s Where condensate return is not adequate, a low water cutoff with pump control, condensate receiver, and condensate boiler feed pump should be installed. s See Figure 19 for piping and Figure 20 for sizing. &IGURE Cold water ﬁll piping &IGURE Condensate piping to boiler (see Figure 18 for cold water ﬁll piping detail) &IGURE Condensate receiver capacity requirements Boiler model number I=B=R gross output (lbs steam per hour) Gallons condensate per hour Minimum condensate receiver capacity (gallons) (Note 1) Recommended condensate feed pump capacity 15-minute boiler GPM at 15 PSI operation 30-minute boiler operation 45-minute boiler operation 60-minute boiler operation 894 2,028 244 74 148 222 296 8.0 994 2,320 279 84 168 252 336 9.0 1094 2,612 314 95 190 285 380 10.5 1194 2,904 349 105 210 315 420 12.0 1294 3,190 383 115 230 345 460 13.0 1394 3,480 418 126 252 378 504 14.0 1494 3,770 453 136 272 408 544 15.0 "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 17 Connect steam boiler piping (continued) &IGURE Model 894 steam (1 riser) &IGURE Model 994 through 2094 steam (2 8-inch risers required) Improperly piped systems or undersized piping can contribute to erratic boiler operation and possible boiler or system damage. Piping system must be installed as shown, using pipe sizes shown. Pipe sizes shown are for two-pipe, pumped-return systems. Adjust pipe sizing as needed when connecting to gravity-return systems. Consult local Weil-McLain distributor or sales ofﬁce before installing alternate piping. Steam boiler piping guidelines -INIMUM HEIGHT OF HEADER ABOVE WATER LINE MUST be 24 inches The boiler header must always be at least INCHES above the water line, as shown in all steam boiler piping diagrams. Installing the pipe lower will result in increased water carryover to the system, resulting in potential seri- ous damage to system components and oxygen corrosion due to excess make-up water. (ARTFORD LOOP PIPING FOR ALL STEAM BOILERS 1. You must install the system supply pipe between the equalizer elbow and the last boiler riser pipe connection to the header. This assists in separating water from the steam as it turns upward into the steam supply pipe. 2. Locate the top of the Hartford loop return nipple at least 4 inches below the water line, as shown. Drawing legend & notes (Figure 21 through Figure 24) Riser pipes (one for each supply outlet) Horizontal pipes needed to offset the header to allow for expansion and contraction of the header Steam supply must be located between last riser connection and equalizer elbow Equalizer elbow — full size or reducing Equalizer pipe Close nipple at Hartford loop tee to reduce water hammer potential Condensate return line (gravity or pumped) Pipe to provide 4 inches between water line and top of Hartford loop return nipple Boiler water line — all automatic water level controls must be set to maintain this level Minimum 24 inches between water line and bottom of header Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 18 Part No. 550-110-275/0810 Connect steam boiler piping (continued) &IGURE Model 2194 through 2594 steam (2 10-inch risers required) Drawing legend & notes (Figure 21 through Figure 24) Riser pipes (one for each supply outlet) Horizontal pipes needed to offset the header to allow for expansion and contraction of the header Steam supply must be located between last riser connection and equalizer elbow Equalizer elbow — full size or reducing Equalizer pipe Close nipple at Hartford loop tee to reduce water hammer potential Condensate return line (gravity or pumped) Pipe to provide 4 inches between water line and top of Hartford loop return nipple Boiler water line — all automatic water level controls must be set to maintain this level Minimum 24 inches between water line and bottom of header "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 19 &ReturnIGURE Multiple Steam Boiler Piping Gravity Condensate Connect steam boiler piping (continued) A Pipe as shown for gravity return systems, connecting point A to the wet gravity return. s For pumped-return systems, install boiler water level control on each boiler with body mark at level indicated in Figure 38, page 30. Provide at point A either: s Separate feed pumps and check valves for each boiler, or . . . s Single feed pump, with separate solenoid valve for each boiler. B For pumped-return systems, install a combination ﬂoat and thermostatic trap on each boiler to prevent ﬂooding of one boiler while other boiler is ﬁring. Install trap in skim tapping. Connect traps to condensate receiver. Gravity-return systems are self-levelling if the wet returns are piped to the common system wet return. C Install boiler piping as shown in the preceding pages of this manual. D Install stop valves per ASME code requirements. s For pump-return systems, if using automatic steam valves, use only slow-opening automatic valves. Use a Weil-McLain Boiler Control System (such as a BCP panel) to open each steam valve automatically before ﬁring burner. E Construct common supply drop header with pipe size at least same size as largest boiler header size. F Use: s A Weil-McLain Boiler Control System (such as a BCP panel) with header-mounted pressure control(s) to sequence boilers, or . . . s A steam pressure controller. G Install drip line in common supply drop header. s Gravity-return: Pipe drip line to wet return. s Pumped-return: Use combination ﬂoat and thermostatic trap and drain to condensate receiver. See page 18 for numbered circle references. Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 20 Part No. 550-110-275/0810 Complete block assembly & install jacket Before installing jacket The boiler contains ceramic ﬁber and ﬁberglass materials. Use care when handling these materials per instructions on page 36 of this manual. Failure to comply could result in severe personal injury. The boiler must be pressure tested before proceeding with jacket installation. See page 11. Failure to comply could result in severe personal injury, death or substan- tial property damage. Read the following before install- ing other controls and trim: 4HESE PARTS -534 BE /. THE boiler: 1. Plugs for unused tappings. 2. Supply and return piping and steam sup- ply header, including supply elbows or top supply adapters. 3. Tankless heaters (when used), tankless heater cover plates (when used). 4HESE PARTS -!9 BE ON THE BOILER 1. Burner mounting plate. 4HESE PARTS -534 BE /&& THE boiler: 1. Cleanout plates and cleanout doors. 2. Access panel. 3. Flue collar. 4. Breeching. 5. Burner. 6. Water or steam gauge. 7. Limit control and low water cutoff. 8. Gauge glass and gauge glass cocks, try cocks. 9. Drain cock. 10. Tankless heater piping (when used). Burner mounting plate 1. The following instructions assume a burner mounting plate supplied with the boiler. For H-94 boilers, if burner mounting plate was not ordered, the plate must be made according to burner requirements. a. Thread two nuts on rounded end of ½" x 4¼" stud, locking them to- gether. Screw ﬂat end of stud in one of six holes around opening. b. Remove nuts from stud and save. c. Repeat for remaining ﬁve studs. d. Apply 1⁄8" continuous bead of rope adhesive in groove around opening. e. Position ½" sealing rope in groove. Overlap ends about 2 inches. f. Install burner mounting plate with observation port at top of plate. Use ½" washers and nuts. Front observation plate 1. Install front observation port assembly over half-moon on burner mounting plate: a. Apply 1⁄8" continuous bead of rope adhesive in groove on assem- bly. b. Position 3⁄8" sealing rope in groove, overlapping ends at least "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 21 Complete block assembly & install jacket (continued) &IGURE Model 94 boiler jacket cartons and contents Carton # Description Contents 94-EP End panel (1) RF front panel | (1) BA back panel | (8) brackets | (47) #10 x ½" type A sheet metal screws (8) #C-8616-5618 Tinnerman speed nuts | (8) 7/16" I.D. x 1 3/8" O.D. x .038" washers (8) 5/16-18 N.C. x 1½" round head screws 94A * Side panel (2) side panels Panel width suffix: A or AK = 30" | B or BK = 36" | C, CK or CKK = 42" | D, DK or DKK = 48" | E, EK or EKK = 54" [Note: suffix "K" means one (1) of the side panels has two (2) tankless heater openings; "CKK or DKK" indicates three (3) tankless openings and "EKK" indicates four (4) tankless openings] 94A Top panel (2) top panels [Suffix "0" indicates top panels have top out cutouts.] 94-SC Splice channel carton (2) side splice channels | (1) top splice channel | (8) brackets | (42) #10 x ½" type A sheet metal screws (8) 5/8"-11 N.C. hex nuts Carton quantities Boiler model End panel cartons Splice channel cartons Side panel cartons Top panel cartons 94-EP 94-SC A BCDEABCDECOEO 8 1- - --1----1--- 9 1- - ---1----1-- 10 11 2 ----2------ 11 11 1 1---11----- 12 11 1 -1--1-1---- 13 11 - 11---11---- 14 11 - -2----2---- 15 11 - -11---11--- 16 11 - -1-1--1-1-- 17 11 - --11---11-- 18 11 - ---2----2-- 19 12 1 -2--1-2---- 20 12 - 12---12---- 3TEAM 12 - -3----1--2- 7ATER 12 - -3----2--1- 3TEAM 12 - -21----1-2- 7ATER 12 - -21---11-1- 3TEAM 12 - -2-1----12- 7ATER 12 - -2-1--1-11- 3TEAM 12 - -111---1-11 7ATER 12 - -111---111- 3TEAM 12 - -1-2----111 7ATER 12 - -1-2----21- * If the boiler was ordered with tankless coil(s), jacket side panel(s) with tankless coil knockout openings will be furnished. It is important that the TI section(s) (where used) be positioned in the exact location(s) in the section assembly as shown in the boiler erecting instructions (see Figure 9, page 10) so the tankless coil knockout openings in the jacket side panel(s) will accommodate the tankless coil(s). If the TI section(s) and tankless coil(s) are not positioned in the boiler section assembly as directed, the installer must cut opening(s) in the jacket side panel(s) to accommodate the coil(s). Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 22 Part No. 550-110-275/0810 Complete block assembly & install jacket (continued) rod nuts. c. When completed, there will be four brackets on each section listed in Figure 26. &IGURE Place support brackets as listed below (sections are numbered from back to front) (see Figure 27) "OILER )NSTALL BRACKETS ON SECTIONS )NSTALL BRACKETS ON SECTIONS 1094 5 & 6 — 1194 5 & 6 — 1294 4 & 5 — 1394 6 & 7 — 1494 7 & 8 — 1595 7 & 8 — 1694 7 & 8 — 1794 8 & 9 — 1894 9 & 10 — 1994 7 & 8 12 & 13 2094 7 & 8 13 & 14 2194 7 & 8 14 & 15 2294 7 & 8 15 & 16 2394 7 & 8 16 & 17 2494 9 & 10 17 & 18 2594 9 & 10 18 & 19 5. Attach the left and right splice channels to the splice channel brackets using two (2) #10 x ½" type A sheet metal screws provided. 6. Attach the top splice channel to the brackets and to the two side splice channels using eight (8) #10 x ½" type A sheet metal screws provided. Install side and top jacket panels 1. Attach jacket side panels to front and rear panels and splice channels using #10 x ½" type A sheet metal screws pro- vided. DO NOT stand on the jacket at any time. Jacket panels will be damaged. 2. For boilers with tankless heaters or tankless heater openings in the sections, make sure to install the side panels with heater openings on the correct side. 3. After jacket side panels are in stalled, install the jacket top panels using #10 x ½" type A sheet metal screws provided. DO NOT loosen the tie rod nuts when installing jacket brackets. Brackets are attached using separate fasteners. Install front and rear jacket panel brackets 1. See Figure 27. 2. Install jacket brackets on the tie rod lugs of the front and rear sections as shown in inset A and inset B of Figure 27. a. Front section brackets must point toward the front. Rear section brackets must point toward the rear. b. Slide one slot of the bracket over the tie rod. c. Secure each bracket using the provided 5⁄16" x 11⁄2" screw, washer and Tinnerman nut as shown. d. Install a bracket to each side tie rod lug and two on the top tie rod lug, totalling four brackets the front section "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 23 &IGURE Installing jacket support brackets, support channels and corners (piping and other components omitted for clarity) Complete block assembly & install jacket (continued) Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 24 Part No. 550-110-275/0810 Complete block assembly & install jacket (continued) Install front cleanout doors 1. See Figure 28, items K20 (cleanout door assembly), K22 (hinge for cleanout door), K22 (hinge for cleanout door) and K24 (hinge plate for cleanout door). 2. Apply a 1⁄8" continuous bead of rope adhesive in the grooves around the cleanout doors. 3. Position 1⁄2" sealing rope in grooves, overlapping ends at least 1". 4. Secure 8 mounting studs in tapped holes located around cleanout openings. 5. Position cleanout door with hinge closest to centerline of front section over 4 studs. 6. Hand tighten 4 wing nuts to secure door to section. 7. Attach cleanout door hinge plate to installed door. Use two hinge pins. 8. Attach other door to hinge plate. Use two hinge pins. 9. Close second door. Hand tighten 4 wing nuts to secure door to section. 10. Afﬁx boiler nameplate to hinge plate. Use 2 drive screws. Install front cleanout plates 1. See Figure 28, item M (cleanout plates). 2. Thread two 1⁄2" nuts on round end of 1⁄2" x 41⁄4" stud. Lock the nuts together. 3. Thread ﬂat end of stud into tapped hole in one of the clean-out openings. 4. Remove nuts. 5. Repeat steps 1-3 for remaining 5 studs. 6. Apply 1⁄8" continuous bead of rope adhesive in groove around plates. 7. Position 3⁄8" sealing rope in groove, overlapping ends at least 1". 8. Insert a cleanout plate into each opening. Secure with hand- tightened wing nut. Install ﬂue collar on rear section 1. See Figure 29, item D (ﬂue collar assembly). 2. Thread two 1⁄2" nuts on round end of 1⁄2" x 41⁄4" stud. Lock nuts together. 3. Thread ﬂat end of stud into tapped hole inside ﬂueway outlet. 4. Remove nuts. 5. Repeat steps 1 through 3 for the remaining 3 studs. 6. Apply 1⁄8" continuous bead of rope adhesive in groove around ﬂue collar. 7. Position 1⁄2" sealing rope in groove, overlapping ends at least 1". 8. Position ﬂue collar over studs. The breeching damper handle must point up. 9. Tightly secure ﬂue collar to rear section using 1⁄2" nuts and wash- ers. Install back access door 1. See Figure 29, items K40 (back access door assembly) and K41(refractory shield for back access door). 2. Insert access door shield into opening in back section. 3. Push against shield until it bottoms against stops. 4. Apply 1⁄8" continuous bead of rope adhesive in groove around back access door opening. 5. Position 1⁄2" sealing rope in groove, overlapping ends at least 1". 6. Secure four mounting studs in holes around back access door opening. 7. Position access door assembly over studs. "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 25 (OT WATER CAN SCALD Consumer Product Safety Commission and some states recommend domestic hot water tempera- ture of 130°F or less. When installing an automatic mixing valve, se- lection and installation MUST comply with valve manufacturer's recommendations and instruc- tions. Water heated to a temperature suitable for clothes washing, dish washing and other sanitizing needs will scald and cause injury. Children, elderly, inﬁrm or physically handi- capped persons are more likely to be injured by hot water. Never leave them unattended in or near a bathtub, shower or sink. Never allow small children to use a hot water faucet or draw their own bath. If anyone using hot water in the building ﬁts this description, or if state laws or local codes require certain water temperatures at hot water faucets, take special precautions: — Install automatic mixing valve set according to those standards. — Use lowest practical temperature setting. — Check water temperature immediately after ﬁrst heating cycle and after any adjustment. To pipe tankless heaters: 1. See Figure 31. 2. Size piping no smaller than heater inlet and out- let. 3. Automatic mixing valve must be installed. See Figure 31. Follow manufacturer's instructions to install. 4. Flow regulating valve must be installed. Size accord- ing to continuous draw of heater. See Figure 30. Follow manufacturer's instructions to install. 5. Operating control with small adjustable differen- tial scale is recommended. Install in temperature control tapping in heater plate. 6. Multiple tankless heaters (see Figure 31): a. Use cold water supply header with individual risers to each heater. Size header by increasing one pipe size for each additional heater. b. Use hot water outlet header with individual risers to each heater. Size header by increasing one pipe size for each additional heater. c. Do not pipe multiple heaters in series. 7. In hard water areas, soften cold domestic water supply to heaters to prevent lime build-up. &IGURE Tankless heater ratings (Weil-McLain ratings) (EATER NUMBER )NTERMITTENT DRAW n '0- NOTE #ONTINUOUS DRAW '0- Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 26 Part No. 550-110-275/0810 Install water boiler controls Install controls: 1. Install furnished controls per Figure 32 and Fig- ure 33, page 27. Failure to properly install, pipe and wire boiler controls can result in severe dam- age to boiler, building and personnel; and is not covered by boiler warranty. 2. Relief valve must be installed with spindle in vertical position. Use ﬁttings provided with boiler. Do not make any other connection in that piping. Relief valve discharge line must be piped using rigid material suitable for 375°F, threaded one end, 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 any obstruction in discharge line. 3. When installing low water cut-off a. Must be installed if boiler is located above radiation level. b. May be required on water boilers by certain state, local or territorial codes or insurance companies. c. Install low water cutoff designed for water installations where shown in Figure 32 and Figure 33, page 27. d. Pipe float-type low water cut-off(s) with offset piping to prevent obstruction of boil- er access and cleanout openings. See Fig- ure 38, page 30. /NE LIMIT CONTROL is supplied with the boiler. A second limit control must be supplied by the installer (ﬁeld installed) to comply with current ASME Boiler and Pressure Vessel Code, Section IV. 4. Dual limit control settings: A ,OW – set according to design requirements. B (IGH – at least 20° higher than low limit, 240°F maximum. 5. Install optional controls per control manufacturer's instructions. &IGURE Model 94 WATER boiler control tappings )TEM &UNCTION 3IZE (Inches NPT) J1 Temperature control or limit ½ * * PLUG these tappings — not used on water boilers ½ - Probe-type low water cutoff 1 - - Float-type low water cutoff or LWCO/feeder combination (use offset piping as shown in Figure 38, page 30) 1 - - 0 OR 2 Temperature control or limit 3 3 P/T gauge or temperature gauge ¾ 4 OR 4 Temperature control or limit — or — "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 27 Install water boiler controls (continued) &IGURE Model 94 WATER boiler control tappings Controls and fittings must not obstruct cleanout openings or pre- vent required access to the boiler or components. Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 28 Part No. 550-110-275/0810 Install steam boiler controls Install controls: 1. Install controls where shown in Figure 34 and Figure 35, page 29. 2. Follow Figure 36, page 29 and Figure 38, page 30 for mounting operating controls and water level controls. Failure to properly install, pipe and wire boiler controls can result in severe dam- age to boiler, building and personnel; and is not covered by boiler warranty. a. Install steam pressure operating and high limit controls and pressure gauge. See Fig- ure 36, page 29. b. Pressure limit control settings: s ,OW – set according to design require- ments. s (IGH – set at least 2 psi higher than low limit, 15 psi maximum. c. Install water level controls and gauge glass per Figure 38, page 30. s Fittings for controls to be furnished by others. s If water level control is not shown in Figure 37, page 30, locate casting mark on control and install per manufacturer's instructions. Do not use water level controls with quick hook-up ﬁttings. Nuisance shutdowns will occur. Install and pipe from relief valve 1. Install relief valve(s) where shown in Figure 34 and Figure 35, page 29. 2. Relief valve must be installed with spindle in verti- cal position. 3. Do not make any other connection in the relief valve connection piping. Pipe relief valve discharge through vertical piping to atmosphere. Use rigid material suitable for 375°F, threaded one end only. Install drain pan elbow to drain conden- sate. Pipe near ﬂoor close to ﬂoor drain to eliminate potential of severe burns. Do not pipe to any area where freezing could occur. Do not plug, valve or place any obstruction in discharge line. &IGURE Model 94 STEAM boiler control tappings )TEM &UNCTION 3IZE (Inches NPT) * * Gauge glass ½ J2 PLUG this tapping — not used ½ - PLUG this tapping — not used 1 - - Float-type low water cutoff, LWCO/pump control or LWCO/feeder combination (see Figure 38, page 30) 1 - - 0 Skim tapping 3 0 Steam pressure relief valve 3 "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 29 &IGURE Model 94 STEAM boiler control tappings Install steam boiler controls (continued) Controls and fittings must not obstruct cleanout openings or pre- vent required access to the boiler or components. &IGURE Steam control siphon and ﬁttings -ANIFOLD COMPONENT SIZING #HECK LOCAL CODES FOR SIZING AND CLEANOUT REQUIREMENTS )TEM $ESCRIPTION 3IZE INCHES n n A Nipple ½ x as needed ¾ x as needed B Plug ½ ¾ C Reducing tee ½ x ½ x ¼ ¾ x ¾ x ¼ D Cross ½ ¾ E Nipple ½ x as needed ¾ x as needed F Nipple ½ x as needed ¾ x as needed G Nipple ½ x as needed ¾ x as needed H Nipple ½ x CLOSE ¾ x 4 K Nipple ½ x 3 [Add a ¾ x ½ bushing at boiler connection] ¾ x 4 Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 30 Part No. 550-110-275/0810 Install steam boiler controls (continued) &IGURE Float-type water level control locations Primary water level control Casting line height above bottom of gauge glass Back-up water level control Casting line height above bottom of gauge glass Note 1 "A" Notes 1, 2 "B" "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 31 Connect breeching and venting systems Seal the venting system gas-tight and connect the breech- ing with welded seams and joints to prevent leakage of combustion products into the boiler room. This is most important for forced draft vent systems. Conventional ﬂue pipe should not be used as it could leak ﬂue gases and carbon monoxide emissions through seams and joints, resulting in severe personal injury or death. General venting information 1. Model 94 boilers operate with positive overﬁre pressure. Adjust damper assembly (see Figure 44, page 35) during burner start-up to achieve 0.1" W.C. positive pressure at damper sample hole. Construct metal breeching: 1. 894-2194 boilers — construct "stub" to attach breeching: a. Use steel breeching-16 ga. or heavier, 20" nominal diameter, minimum 6-inch length (so damper can open). b. Unbolt the breeching counterﬂange from ﬂue collar ﬂange. c. Insert or butt the breeching stub against counter ﬂange so stub is square to ﬂange. Stub must not extend past the face of the ﬂange. d. Weld stub to ﬂange gas-tight. Use caution when welding to avoid warping the ﬂange due to excessive heat accumulation. Flue collar ﬂange Counterﬂange (8) ½" x 1½" machine bolts, nuts and washers Sealing rope, 3⁄8" diameter Gas-tight weld to breeching adapter pipe 20-inch diameter breeching pipe, min. 6" long (by installer) e. Make sure the sealing rope is intact on the ﬂue collar ﬂange. f. Attach the ﬂange/stub assembly to the ﬂue collar using ½" x 1½" machine bolts and washers provided. The connection must be gas-tight. 2. 2294-2594 boilers — attach factory-supplied breeching adapter: a. The boiler is supplied with a ﬂanged breeching adapter 22-inch diameter x 12 inches long. b. Make sure the sealing rope is intact on the ﬂue collar ﬂange. c. Attach the ﬂange/stub assembly to the ﬂue collar using ½" x 1½" machine bolts and washers provided. The connection must be gas-tight. 3. See Figure 39 for minimum breeching diameter. 4. Select material type and thickness in compliance with local codes. 5. Refer to ASHRAE Guide for chimney and breeching calculations and construction and lining. Long horizontal breechings, excessive number of tees and elbows or other obstructions restricting combustion gas ﬂow can result in possibility of condensation, ﬂue gas leakage and carbon monoxide emissions, causing severe personal injury or death. &IGURE Minimum breeching diameter Boiler model I=B=R vent or liner diameter Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 32 Part No. 550-110-275/0810 Connect breeching and venting systems &IGURE Conventional chimney — balanced draft with barometric draft control when required — single boiler &IGURE Stub vent — forced draft — single boiler &IGURE Conventional chimney — balanced draft with barometric draft control when required — multiple boilers "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 33 Install burner & wiring and ﬁll system To install burner 1. Unpack burner. 2. Place gasket around air tube and against burner mounting ﬂange. If sealing rope is used, apply 1⁄8" continuous bead of rope adhesive around burner mounting ﬂange and apply sealing rope to make gas-tight seal. 3. Mount burner into opening in burner mounting plate. Maintain gas-tight seal between burner mounting ﬂange and plate to prevent damage to air tube. 4. Level burner using burner support brackets where required. 5. Secure with furnished bolts. 6. Retain burner information packet. Keep with boiler. To wire burner and boiler controls Electric shock hazard. Can cause severe personal injury or death if power source is not disconnected before installing or servicing boiler and burner. 1. Install all wiring in compliance with: s National Electrical Code ANSI/NFPA 70. s Any additional national, state, or local codes. 2. Follow burner manual and wiring diagram found in burner in- formation packet. 3. Use #14 AWG wire for operating and safety circuit wiring. 4. Where burner motor voltage differs from control voltage, supply proper voltage to each. Size fused disconnects and conductors per National Electrical Code ANSI/NFPA 70. Determine if water treatment is needed (water boilers only) Do not use petroleum-based cleaning or sealing com- pounds in boiler system. Severe damage to system components can result, causing substantial property damage. Continual make-up water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron and causing section failure. For unusually hard water areas or low pH conditions (less than 7.0) consult local water treatment company. Provide a water softener for make-up water if hardness exceeds 7 grains. Freeze protection (when used) (water boilers only) 1. Use antifreeze especially made for hydronic systems. Inhibited propylene glycol is recommended. Do not use automotive, ethylene glycol or undiluted antifreeze. Severe personal injury or death can result. 2. 50% solution provides protection to about -30°F. 3. Local codes may require back-ﬂow preventer or actual disconnect from city water supply. 4. Determine quantity according to system water content. Boiler water content is listed in "Ratings," page 41. Percent of solution will affect sizing of heat distribution units, circulator and expansion tank. 5. Follow antifreeze manufacturer's instructions. To ﬁll water boilers 1. Close manual air vents and drain cocks. 2. Fill to correct system pressure. Correct pressure will Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 34 Part No. 550-110-275/0810 Install fuel piping 'AS PIPING 1. In sizing the gas piping, the following factors should be consid- ered: a. Diameter and length of the gas supply piping. b. Number of ﬁttings. c. Maximum gas consumption (including any possible future expansion). d. Allowable loss in gas pressure from the gas meter outlet to the boiler. 2. Minimum inlet natural gas pressure required at manual main shut- off valve — see the burner manual and material list. 3. Follow good piping practices. 4. Pipe joint compound (pipe dope) must be resistant to the corrosive action of liqueﬁed petroleum gases and applied sparingly only to the male threads of pipe joints. 5. A ground joint union must be installed in the piping to provide for servicing. The supply piping must include a manual shut-off valve and sediment trap. See Figure 43. 6. Piping must be supported by hangers, not by the burner or its accessories. 7. Purge all air from the supply piping. 8. All gas piping must be tested for leaks after installation. Use soap suds mixture only. Fuel oil piping To prevent oil ﬂow in case of oil line breakage: s 5SE ANTI SYPHON DEVICE WHEN ANY PART OF THE OIL TANK is above burner level. s 5SE CHECK VALVE IN SUCTION LINE ON BURNER SIDE OF manual shut-off valve nearest tank when top of fuel oil tank is below burner level. Failure to comply could result in fuel leakage or ﬁre, caus- ing potential severe personal injury, death or substantial property damage. 1. A two-pipe fuel oil piping system is required for all installations. 2. Supply and return lines must enter tank from top, extending to within 4 to 6 inches from bottom of tank. 3. Use oil ﬁlter sized for fuel pump suction gear capacity. 4. Install oil ﬁlter. Do not install ﬁlter outside or close to an outside wall. 5. Use continuous copper tubing to reduce possible piping leaks and to ensure reliable seal when oil piping is buried. 6. Use ﬂare ﬁttings, not compression ﬁttings. &IRE HAZARD — DO NOT USE soldered ﬁttings. No safe repair can be made. 7. Follow good piping practices. 8. Pipe joint compound (pipe dope) must be resistant to corrosive action of fuel oil. Apply sparingly only to male threads of pipe joints. 9. Supply and return piping should be sized to design conditions, but not less than ½" O.D. continuous copper tubing. 10. Auxiliary fuel oil pump is recommended when suction line lift exceeds 12 feet. 11. Install swing joints so they will tighten as buried tank settles to prevent fuel line breakage. 12. Where iron pipe is required by local codes, make "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 35 Make ﬁnal adjustments &IGURE Flue collar/damper assembly Test plug Damper locking cap nut Adjust burner and damper assembly: 1. Lock ﬂue damper OPEN ( Figure 44). Make ﬁnal burner adjustments using combustion test equipment to assure proper operation. Do not ﬁre boiler without water. Sections will overheat, damaging boiler and resulting in severe property damage. 2. Refer to burner manual for start-up and service. 3. Let burner advance to high ﬁre. Heat boiler to design conditions. 4. Using combustion test equipment, adjust burner for: a. 12% (± ¼%) CO 2 for No. 2 fuel oil, 0 smoke. b. 9 – 10% CO 2 natural gas; CO in ﬂue gas not to exceed 50 ppm (0.01%). c. &LUE GAS TEMPERATURE NO LOWER THAN & On some applications, if draft conditions or burner char- acteristics cause the burner ﬂame pattern to impinge on the combustion chamber wall, you may notice pinging sounds from the boiler. Adjust the burner if possible to redirect the ﬂame. If this does not work, contact your boiler supplier or Weil-McLain to obtain an optional combustion chamber kit (see page 44 for contents). 5. Adjust ﬂue collar damper ( Figure 44) to ensure 0.1" W.C. positive pressure at test opening. 6. Tighten screws to secure in position. 7. Plug test opening with 1⁄8" plug provided with ﬂue collar/damper assembly. 8. Adjust barometric draft control, when used, to design condi- tions. 9. Repeat steps 4 through 6. Adjust as required. Skim steam boilers: Clean all newly installed steam boilers to remove oil. Failure to properly clean can result in violent water level ﬂuctuations, water passing into steam mains, or high maintenance costs on strainers, traps and vents. Skim boiler only. Do not clean old piping or leaks can occur. Do not use petroleum-based cleaning or sealing com- pounds in boiler system. Severe damage to system components can result, causing substantial property damage. 1. Provide 4" skim piping from tapping to ﬂoor drain. 2. Raise waterline to midpoint of skim piping. 3. Fire burner to maintain temperature below steaming rate during skimming process. 4. Feed in water to maintain water level. 5. Cycle burner ON/OFF as needed to prevent rise in steam pres- sure. 6. Continue skimming until discharge is clear. This may take several hours. 7. Drain boiler at cleanout tappings. 8. While boiler is warm, BUT NOT HOT, ﬂush all inte- rior surfaces under full pressure until drain water runs clear. Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 36 Part No. 550-110-275/0810 Handling ceramic ﬁber and ﬁberglass materials REMOVAL OF REFRACTORY OR CERAMIC INSULATION MATERIALS The burner front plate and cleanout plates contain ceramic ﬁber materials. Ceramic ﬁbers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).": N Avoid breathing dust and contact with skin and eyes. s 5SE .)/3( CERTIlED DUST RESPIRATOR . 4HIS TYPE OF RESPIRATOR IS BASED ON THE /3(! RE- quirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this web site. s 7EAR LONG SLEEVED "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 37 &IGURE Service and maintenance schedules 3ERVICE TECHNICIAN (see following pages for instructions) /WNER MAINTENANCE ANNUAL START-UP PROCEDURES (or as required by conditions) )NSPECTION ALL BOILERS t Discuss any reported problems with owner/operator. t Inspect burner and ﬂueways. t Clean boiler heating surfaces and burner if necessary, following procedures provided in this manual. t Check for water leaks in piping and at components. t Check gas piping for leaks using soap suds mixture only. t Check oil piping, tank and components for signs of leakage. t Inspect wiring and connections. t Lubricate circulators and pumps as required; perform maintenance required for all system components. )NSPECTION WATER BOILERS t Check system water pressure, system piping and expansion tank. t Open boiler drain cock to remove impurities that have settled to the bottom of the boiler. Reﬁll to the correct working pressure. t Check system water chemistry, inhibitor level and antifreeze concentration, if used. )NSPECTION STEAM BOILERS t Check for indications of operating problems, excessive make-up, etc. t Check control settings. t Inspect control piping and low water cut-oﬀ(s). Clean if necessary, following procedures in this manual. 3TART UP t Follow procedures on page 35 to start-up boiler and test operation. t Skim steam boilers as described on page 35. t Test the low water cutoﬀ by opening its blowdown valve to remove dirt, rust, and sediment. Verify that burner stops as the water level approaches the bottom of the water gauge glass. t Verify operation of boiler and all controls. t If operational problems are observed, correct the problems and re-start. 2EVIEW t Review with owner. $AILY t Inspect boiler area — must be free of combustible materials, gasoline and other ﬂammable vapors or liquids. t Inspect combustion air openings. t Check pressure/temperature gauge (or pressure gauge). t Verify boiler is operating correctly. t Steam boilers — check water level in gauge glass. -ONTHLY Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 38 Part No. 550-110-275/0810 Maintenance and troubleshooting (continued) Water chemistry and make-up Do not use petroleum-based clean- ing or sealing compounds in boiler system. Severe damage to system components can result, causing substantial property damage. Leaks in the boiler and piping sys- tem must be repaired at once. If a leak is detected around a gasket (i.e. tankless heater, supply outlet, etc.) tighten evenly and only enough to stop the leak Over-tightening can ruin a gasket. The constant addition of makeup water may damage the boiler. If serious leaks occur, stop the burner. Then gradually reduce boiler pressure or temperature. Do not attempt to make repairs while the boiler is hot or under pressure. If the boiler or system are experienc- ing large amounts of makeup water, extreme foaming or priming, scale in the boiler, or internal corrosion or pitting, contact a company special- izing in boiler water chemistry. DO NOT try "homemade cures" or boiler "patent medicines" on the market under various trade names, as serious damage to the boiler, per- sonnel, and property may result. Failure to comply with the above could result in severe personal in- jury, death or substantial property damage. Read before proceeding The boiler must be inspected, cleaned as necessary, started up and adjusted by a qualiﬁed boiler service technician. %LECTRICAL SHOCK HAZARD — Dis- connect electrical supplies to the boiler before servicing. %XPLOSION HAZARD — Shut off the fuel supply to the boiler while servic- ing. "URN HAZARD — Allow the boiler to cool before touching boiler surfaces or contacting boiler water. The boiler area must be kept clear of combustible materials, gasoline or other ﬂammable vapor or liquids. Do not block the ﬂow of air to the burner. Incomplete combustion, ﬂue gas spillage and carbon monoxide emissions can occur. Label all wires before disconnecting "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 39 Cleaning boiler heating surfaces and ﬂueways Do not brush or vacuum the ﬁrebox or combus- tion chamber area of those boilers using ﬁbrous combustion chamber material. Do not use stick-type thermal bombs in this boiler. 1. Soot is an effective insulator and prevents ﬂue gases from heating the boiler water as efﬁciently as possible. The fre- quency of cleaning will depend upon the fuel used, the burner adjustments, boiler temperature, draft conditions, and other job factors. 2. Remove top or side jacket panel(s). 3. Remove the ﬂueway opening cover(s). 4. Cover the burner and controls. 5. Using a wire ﬂue brush, thoroughly brush the ﬂueways at all angles. 6. Remove any soot or scale from the horizontal and/or vertical ﬂueways, the boiler ﬁrebox. 7. Remove access panel and enter the boiler to clean combustion chamber with special ﬂue brushes provided. 8. Clean the base of the chimney using a vacuum cleaner or brush. 9. Replace the ﬂueway opening cover(s), access panels and jacket panel(s), making sure the original gas-tight seal is maintained. 10. If additional cleaning is required: a. Replace access panels and start the boiler following all instructions in this manual. b. Heat the boiler water to 180°F. Then turn the boiler off, disconnect electrical power and fuel supplies. c. Remove the ﬂueway opening covers. d. Use a garden sprayer or connect a spray nozzle to a garden hose and spray the sooted ﬂueways with a ﬁne mist of water. e. The soot will become loosened and fall to the ﬂoor of the ﬁrebox and around the horizontal ﬂueways. f. Remove the loosened soot. Seasonal boiler shutdown DO NOT DRAIN BOILER during periods of shut- down unless exposed to freezing temperatures. If boiler is shut down during severe winter weather, have the heating system inspected periodically or thoroughly drain the heating and plumbing system following the instructions in this manual for long- term shutdown. 1. Turn off all power supplies to the boiler and its compo- nents. 2. Close all fuel valves. 3. Cover the burner to protect it from dust and dampness. 4. Steam boilers — open boiler blowdown valve and ﬂush till clear while under steam pressure. 5. Water boilers — open the boiler drain cock to remove im- purities. It may be necessary to drain several gallons of water until all traces of sediment are gone. Reﬁll the boiler to the proper water level or pressure. Boiler water does not have to be crystal clear for Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 40 Part No. 550-110-275/0810 If gauge glass breaks, close off both gauge cocks and loosen the glass retaining nuts to remove gauge glass. Replace broken gauge glass with new gauge glass made of heavy-walled Pyrex. DO NOT USE THIN GLASS TUBING. Checking the relief valve 1. Manually open the safety valve once each year by pulling the valve lever or handle and allowing a small amount of steam to escape. 2. Be sure that the valve reseals properly and does not leak. 3. If the relief valve sticks or appears to be clogged, replace immediately. Automatic air vents 1. With the system ﬁlled with water, loosen the air vent cap slowly so that particles of dirt or scale are not deposited on the valve seat by the escaping air. 2. Should dirt or scale lodge on the valve seat, causing it to leak, remove the cap and press the inner stem with a screwdriver or other tool to permit water to ﬂush the valve seat clean. 3. Release the stem quickly and replace the cap. 4. For normal operation and venting, unscrew the cap at least two turns. Troubleshooting — steam boiler priming or foaming 1. Foaming or priming in a steam boiler can cause large quanti- ties of water to pass into the steam mains, resulting in violent ﬂuctuations of water level in the gauge glass. 2. This trouble may be caused by dirt, oil, or other impurities in the boiler water, too high a boiler water level, a high overload on the boiler (i.e., the sudden release of boiler steam pressure into the mains by action of fast operating valves), or the ad- dition of too much boiler water treatment. 3. With serious foaming or priming, stop the burner and de- crease boiler load. 4. Then alternately blowdown and slowly feed fresh water several times. 5. If trouble persists, it may be necessary to skim the boiler one or more times. Troubleshooting —relief valve opens frequently or weeps 1. Expansion tank may be water-logged in it closed type (air- head type) 2. Bladder or diaphragm-type expansion tank may have punc- tured membrane or may have incorrect charge pressure — follow tank manufacturer's instruction to troubleshoot and set charge pressure. Maintenance and troubleshooting (continued) "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 41 Ratings Boiler model number I=B=R burner capacity Gross I=B=R output Net I=B=R ratings Net Sq. Ft. Water Boiler H.P. Combustion efﬁciency Thermal efﬁciency Net ﬁrebox volume Flue gas volume Positive pressure in ﬁrebox Draft loss through boiler Flue outlet diameter Boiler water content Light oil GPH Heavy oil GPH Gas MBH MBH Steam Sq. Ft Steam MBH Water MBH Oil Gas Oil Gas Cubic feet CFM Inches W.C. Inches W.C. Inches Gallons Notes: Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 42 Part No. 550-110-275/0810 Dimensions Dimensions (inches) Model ! (steam only) BCDE J (steam only) LW Water 3TEAM Water 3TEAM 894 775⁄8 711⁄16 711⁄16 45 — — 76 — 521⁄2 51 994 835⁄8 711⁄16 711⁄16 51 — — 76 163⁄8 581⁄2 57 1094 895⁄8 711⁄16 711⁄16 57 — — 76 163⁄8 641⁄2 63 1194 955⁄8 711⁄16 711⁄16 63 — — 76 163⁄8 701⁄2 69 1294 1075⁄8 711⁄16 711⁄16 69 — — 76 163⁄8 761⁄2 75 1394 1135⁄8 83⁄8 711⁄16 75 — — 76 163⁄8 821⁄2 81 1494 1195⁄8 83⁄8 711⁄16 81 — — 76 163⁄8 881⁄2 87 1594 1255⁄8 83⁄8 711⁄16 87 — — 76 163⁄8 941⁄2 93 1694 1315⁄8 83⁄8 711⁄16 93 — — 76 163⁄8 1001⁄2 99 1794 1195⁄8 83⁄8 711⁄16 99 — — 76 163⁄8 1061⁄2 105 1894 1255⁄8 83⁄8 711⁄16 105 — — 76 163⁄8 1121⁄2 111 1994 1315⁄8 83⁄8 711⁄16 111 — — 76 163⁄8 1181⁄2 117 2094 1375⁄8 83⁄8 711⁄16 117 — — 76 163⁄8 1241⁄2 123 2194 1435⁄8 83⁄8 711⁄16 123 171⁄4 211⁄4 821⁄2 — 1301⁄2 129 2294 72 83⁄8 711⁄16 129 171⁄4 211⁄4 821⁄2 — 1361⁄2 135 2394 84 83⁄8 711⁄16 135 171⁄4 211⁄4 821⁄2 — 1421⁄2 141 2494 90 83⁄8 711⁄16 141 171⁄4 211⁄4 821⁄2 — 1481⁄2 147 2594 96 83⁄8 711⁄16 147 171⁄4 211⁄4 821⁄2 — 1541⁄2 153 Model 3UPPLY RETURN TAPPINGS All 6" are tapped | All 8" and 10" are ﬂanged "URNER LENGTHS Dimension & Supply tappings (No. & size) Return tappings (No. & size) Steam Water Steam Water 894 1 – 8" 1 – 6" 1 – 6" 1 – 6" Refer to burner speciﬁcation and data sheet for dimensional information on the burner. 994 2 – 8" 1 – 6" 1 – 6" 1 – 6" 1094 2 – 8" 1 – 6" 1 – 6" 1 – 6" 1194 2 – 8" 1 – 6" 1 – 6" 1 – 6" 1294 2 – 8" 1 – 6" 1 – 6" 1 – 6" 1394 2 – 8" 1 – 8" 1 – 6" 1 – 8" 1494 2 – 8" 1 – 8" 1 – 6" 1 – 8" 1594 2 – 8" 1 – 8" 1 – 6" 1 – 8" 1694 2 – 8" 1 – 8" 1 – 6" 1 – 8" 1794 2 – 8" 1 – 8" 1 – 6" 1 – 8" 1894 2 – 8" 1 – 8" 1 – 6" 1 – 8" 1994 2 – 8" 1 – 8" 1 – 6" 1 – 8" 2094 2 – 8" 1 – 8" 1 – 6" 1 – 8" 2194 2 – 10" 1 – 10" 1 – 6" 1 – 10" 2294 2 – 10" 1 – 10" 1 – 6" 1 – 10" 2394 2 – 10" 1 – 10" 1 – 6" 1 – 10" 2494 2 – 10" 1 – 10" 1 – 6" 1 – 10" 2594 2 – 10" 1 – 10" 1 – 6" 1 – 10" "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 43 Dimensions (continued) &IGURE Dimensions (INCHES) (see lettered dimensions on opposite page) Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 44 Part No. 550-110-275/0810 Parts Item Description Part No. A Front section (casting # 9517) 318-102-505 B Back section water & steam w/8” round return ﬂange (casting # 9518) 318-102-515 B Back section water only for 10” square return ﬂange adapter (casting # 95218) 318-102-525 C Regular intermediate section (casting # 9515) 318-102-535 C1 Tankless intermediate section (casting # 9516) 318-102-545 C2 Supply intermediate sections (casting # 9519) 318-102-575 6” bottom elastomer seal (2 per joint) 592-800-007 9” top elastomer seal (1 per joint) 592-800-005 5/8” x 10” draw rod without nut (4 per joint) intermediate to intermediate 560-134-490 5/8” x 11” draw rod without nut (4 per joint) front or back to intermediate 560-134-495 5/8” hex nut (2 per draw rod) 561-928-224 5/8” washer, plain, ASTM F-436 (1 per draw rod) 562-248-710 Flue brush 591-706-185 Flue brush rod, 44” 591-706-222 Flue brush rod, 62” 591-706-223 Flue brush spacer, 48” 591-706-240 Flue brush handle, ﬂexible wire 591-706-226 1/8” diameter sealing wick (3’ for front observation port, 1’ for relief plate, 1’ for damper locking plate 590-735-145 3/8” diameter sealing rope (6’ for rear access shield, 2’ for rear observation port, 2’ for front observation port, 12’ for draft hood counter ﬂange, 3’ per cleanout plate 590-735-150 5/8” diameter Silicone coated rope for ﬁrebox perimeter, 22’ length 590-735-154 5/8” diameter Sealing rope, 12’ length, for ﬂue way perimeter 590-735-153 Construction adhesive for rope (11 oz. caulking tube) 591-641-850 Silicone sealant (RTV 108 or equivalent) (3 oz. tube) (approximately .47 oz. per joint) 591-638-851 K40 Back access door assembly (includes door liner, handle and rope) 340-004-700 Refractory liner for back access door 387-834-906 Mounting stud (4 required for access door) 560-340-560 K41 Refractory shield for back access opening 387-834-905 M Cleanout plate (casting # 9254) 330-061-000 Wing Nut for cleanout with ½” tapping 330-060-700 Stud ½”-13 x 4 ¼” long 560-340-570 K20 Cleanout door assembly 474, includes door, hinge, hinge plate, handle, liner and accessories 340-004-740 Item Description Part No. Wing nut assembly — with 3/8 x 1 ¼’ stud (threads into mounting stud) (casting # 9256) 340-004-635 "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 45 Parts (continued) &partsIGURE Block assembly Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 46 Part No. 550-110-275/0810 Parts (continued) &IGURE WATER boiler trim and control components Item Description Manufacturer Mfr's part number Weil-McLain part number Boiler size 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 ASME Pressure Relief Valve, 1" inlet x 1¼" side outlet, Brass, 30 PSIG Watts 740 511-546-930 1 1 1 ASME Pressure Relief Valve, 1¼" inlet x 1½" side outlet, Brass, 30 PSIG Watts 740 511-546-935 1 1 1 ASME Pressure Relief Valve 1½" inlet by 2" side outlet, Brass, 30 PSIG Watts 740 511-546-940 1 1 2 ASME Pressure Relief Valve, 2" inlet by 2½" Side outlet, Brass, 30 PSIG Watts 740 511-546-945 111111111 11111 2 Combination Pressure-Temperature gauge: 0-55 PSIG, 60-260°F. 0-148 ft., Back Connection, ½" NPT ENFM 4104-3.25 510-218-065 111111111111111111 Ametek PT 1088 3 Combination High Limit-Low Limit Control Honeywell L4081A-1189 with well 510-312-065 111111111111111111 Carlin 90000CEC 90000C 90000E 111111111111111111 "OILER MANUAL s )NSTALLATION s 3TART 5P s -AINTENANCE s 0ARTS Part No. 550-110-275/0810 47 Parts (continued) &IGURE STEAM boiler trim and control components Item Description (note = alternate components) Manufacturer Mfr's part number Weil-McLain part number Boiler size 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 Gage glass 5⁄8" diameter X 105⁄8" long Weil-McLain 383-600-002 111111111111111111 2 Gage glass guards, 3⁄16" diameter X 121⁄2" long Weil-McLain 563-334-595 111111111111111111 3 Combination pressure-vacuum gauge, 0–30 psig, 0–30" Hg, 41⁄2" diameter, bottom connection, 1⁄4" NPT Ametek ASC500-5549 510-218-100 1 1 1111111111111111 4 (note) Water gage glass cocks, set ½" NPT, Male inlet Conbraco 21-205-03W 510-218-145 111111111111111111 5 (note) High pressure limit, 0 to 15 psig adjustable, subtractive differential 2 to 8 psig. Open on high pressure switch action. Johnson Controls P47EA-3D 510-312-135 222222222222222222 Honeywell PA404A-1009 6 Steam safety valve 1¼"" inlet, 15 psig, side outlet, 1200 lbs/hr capacity Conbraco 13-213-08 511-548-051 1 1 Steam safety valve 1½"" inlet, 15 psg, side outlet, 1900 lbs/hr capacity Conbraco 13-214-08 511-548-052 112211 1 Steam safety valve 2" inlet, 15 psig, side outlet, 2500 lbs/hr capacity Conbraco 12-205-08 511-548-056 1 1 11222 11 Steam safety valve 2½" inlet, 15 psig, side outlet, 3529 lbs/hr capacity Conbraco 12-206-08 511-548-057 1112222 Weil-McLain 94 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 48 Part No. 550-110-275/0810 Mounting stud, ½"-13 x 21⁄8" long 560-340-560 K22 Hinge for cleanout door (casting # 9254) 330-060-500 K24 Hinge plate for cleanout door (casting # 9253) 330-060-400 Liner for cleanout door 590-524-867 L Heater cover plate carton (includes cover plate, studs, nuts, and gasket) 387-800-500 L1 Gasket for heater cover plate 590-317-544 F3 Front observation port assy. #462 (includes bottom, intermediate, & top observation port plates, spring, rope, & sight glass 340-004-620 Front sight glass 591-419-198 F4 Back observation Port assembly (includes frame, rope, gasket, plugs, and sight glass) 385-600-099 Back sight glass 591-419-199 Gasket for back sight glass 590-317-580 D Flue collar assembly 20” (includes ﬂue collar w/ﬂange, damper, damper quadrant, locking plate, swivel, bracket, counter ﬂange, and rope 340-004-616 Quadrant for ﬂue collar 330-056-634 Damper blade for ﬂue collar 460-003-640 Damper locking plate 563-530-784 Stud, ½”-13 x 4 ¼” long 560-340-570 D1 Counter ﬂange for 20” ﬂue 460-030-930 D2 Flue adapter, 22” welded steel 460-030-936 O1 Return ﬂange reducer, 8” to 6” (includes hardware and gasket) 388-135-300 O2 Gasket for return ﬂange reducer, round 590-317-572 O3 Return ﬂange adapter, 10” 330-062-001 O4 Gasket for return ﬂange adapter, rectangular 590-317-620 N 6” supply elbow tapped, water only (casting # 9246) 330-060-200 8” supply elbow tapped, water only (casting # 9248) 330-060-300 8” supply elbow tapped, steam only (casting # 92481) 330-060-310 N1 Gasket for supply outlet (2 required) 590-317-546 Stud, 5/8”-11 x 3” long 560-340-579 N2 Cover plate for supply outlet, 2” (casting # 9440) 330-062-005 N2 Cover plate for supply outlet, 4” (casting # 92140) 330-059-910 N3 Top supply outlet, 10” ﬂanged (casting # 92410) 330-060-210 N4 Gasket for top supply outlet, 10” (2 required per ﬁtting) 590-317-625 P Tankless heater (when used) — heater, gasket, nuts and studs 590-921-910 1, 10 2, 32, 3, 112, 45, 6, 11 8, 118, 118, 1112—————— 7 9 — — — ( 17.6 16.6 2540 2028 6563 1575 1763 11753 60.6 84.0 81.0 83.0 81.0 45.40 1088 0.275 0.175 20 274.3 ( 20.0 19.0 2887 2320 7504 1801 2017 13447 69.3 84.0 81.0 83.0 81.0 51.48 1242 0.315 0.215 20 302.0 ( 22.5 21.5 3247 2612 8450 2028 2271 15140 78.0 84.0 81.0 83.0 81.0 57.56 1397 0.355 0.255 20 329.8 ( 25.0 24.0 3608 2904 9396 2255 2525 16834 86.7 84.0 81.0 83.0 81.0 63.64 1555 0.395 0.295 20 357.5 ( 27.5 26.0 3969 3190 10321 2477 2774 18494 95.3 84.0 81.0 83.0 81.0 69.72 1710 0.435 0.335 20 385.2 ( 30.0 28.5 4330 3480 11258 2702 3026 20174 104.0 84.0 81.0 83.0 81.0 75.80 1866 0.475 0.375 20 413.0 ( 32.5 31.0 4691 3770 12196 2927 3278 21854 112.6 84.0 81.0 83.0 81.0 81.88 2020 0.515 0.415 20 440.7 ( 35.0 33.0 5052 4070 13167 3160 3539 23594 121.6 84.0 81.0 83.0 81.0 87.96 2175 0.555 0.455 20 468.4 ( 37.5 35.5 5412 4360 14104 3385 3791 25274 130.2 84.0 81.0 83.0 81.0 94.04 2325 0.585 0.485 20 496.2 ( 40.0 38.0 5773 4650 15042 3610 4043 26954 138.9 84.0 81.0 83.0 81.0 100.12 2480 0.625 0.525 20 523.9 ( 42.5 40.5 6134 4940 15979 3835 4296 28640 147.6 84.0 81.0 83.0 81.0 106.20 2640 0.665 0.565 20 551.6 ( 45.0 42.5 6495 5230 16921 4061 4548 30320 156.2 84.0 81.0 83.0 81.0 112.28 2795 0.705 0.605 20 579.4 ( 47.5 45.0 6856 5520 17858 4286 4800 32000 164.9 84.0 81.0 83.0 81.0 118.36 2945 0.750 0.650 20 607.1 ( 50.0 47.4 7216 5810 18796 4511 5052 33680 173.6 84.0 81.0 83.0 81.0 124.44 3120 0.850 0.750 20 634.8 ( 53.0 49.8 7649 6100 19733 4736 5304 35360 182.2 84.0 81.0 83.0 81.0 130.52 3255 0.950 0.850 20 * 662.6 ( 55.0 52.2 7938 6390 20671 4961 5557 37047 190.9 84.0 81.0 83.0 81.0 136.60 3410 1.050 0.950 20 * 690.3 ( 58.0 54.6 8371 6680 21608 5186 5809 38727 199.6 84.0 81.0 83.0 81.0 142.68 3565 1.150 1.050 20 * 718.0 ( 60.0 57.0 8660 6970 22546 5411 6061 40407 208.2 84.0 81.0 83.0 81.0 148.76 3730 1.250 1.150 20 * 745.8 1. See below to specify complete model number. For T-intermediate sections(s) and tankless heater(s), add sufﬁx "(number required) TIH"; for T-intermediate section(s) with cover plates only, add sufﬁx "(number required) TIP" 2. Burner input based on maximum of 2,000 feet altitude. For other altitudes, consult Weil-McLain distributor/agent or sales ofﬁce. 3. No. 2 fuel oil — Commercial Standard Spec CS75-56. Heating value of oil = 140,000 Btu per gallon. No. 4 or No. 5 oil — Commercial Standard Spec CS75-56. Heating value of oil = 150,000 Btu per gallon. 4. Gas pressure required at burner gas train inlet for rated burner input; based on 1,000 Btu per cubic foot natural gas, speciﬁc gravity of 0.60. Refer to burner manual for required pressure. 5. Gross I=B=R ratings have been determined under the I=B=R provision governing forced draft boiler-burner units. 6. Based on average water temperature of 170°F in heat distributing units. 7. Flue gas volume at outlet temperature. 8. Net I=B=R ratings are based on net installed radiation of sufﬁcient quantity for the requirements of the building. Nothing need be added for normal piping and pick-up. Water ratings are based on a piping and pick-up allowance of 1.15. Steam ratings are based on the following allowance of 1.288. An additional allowance should be made for gravity hot water systems or for unusual piping and pick-up loads. Consult local Weil-McLain distributor/agent or sales ofﬁce. 9. With 0.10" W.C. positive pressure at ﬂue collar. 10. Water boilers tested for 80 PSIG, ASME water working pressure. Steam boilers tested for 15 PSIG, ASME steam working pressure. 11. Heavy oil burner ratings are Weil-McLain certiﬁed for 2194–2594. 12. Based on 170°F average water temperature in heat distributing units. * Models 2294–2594 are supplied with 22-inch adapter. proper operation, but should be free of sludge or sediment. Long-term boiler shutdown 1. When the boiler and system must be drained for long-term shutdown, perform the following procedures. 2. Turn off all power supplies to the boiler and its compo- nents. 3. Close all fuel valves. 4. Cover the burner to protect it from dust and dampness. 5. Clean all carbon, rust, and other deposits from the ﬁre-side of the boiler heating surfaces in order to protect the boiler from the corrosive action of combustion deposits. Follow the procedure in this manual under " Cleaning boiler heat- ing surfaces." 6. Apply a thin coating of oil or grease to heating surfaces if the boiler is to remain out of service for an extended time. 7. Drain the boiler and system as necessary. To inspect water side of boiler 1. If the water side of the boiler must be cleaned or inspected, open the blowdown valve and drain the boiler. 2. Hose the inside of the boiler with high pressure water to remove sludge and sediment. Then ﬂush. 3. Dry the boiler water side thoroughly, or reﬁll with fresh water and heat to release dissolved gases, following the procedures in this manual for ﬁlling the system. Repeated draining and ﬁlling of the boiler and/ or the heating system can lead to the same conse- quences as adding too much makeup water. This is worst where the makeup water is hard. Cleaning ﬂoat-type low water cut-offs 1. Accumulated sediment in the low water cut-off should be ﬂushed out through a blow-off valve provided for this pur- pose at least once each month of heating system operation. Cleaning the gauge glass 1. Close the lower gauge glass cock and carefully open the pet- cock below the glass to blow water and sediment out of the gauge glass by steam pressure. 2. Then slowly open the lower gauge glass cock, allowing a small amount of water to ﬂush out through the open petcock. 3. Close the petcock and fully open the lower gauge cock. 4. The water level should immediately rise to its proper level. Maintenance and troubleshooting (continued) for service. Wiring errors can cause improper operation. Verify proper operation of the boiler and system after servicing. The boiler contains ceramic ﬁber and ﬁberglass materials. Follow the instructions on page 36. Failure to comply with the above could result in severe personal in- jury, death or substantial property damage. t Inspect vent piping. t Inspect relief valve. t Water systems — inspect automatic air vents (if used). t Probe-type low water cut-oﬀ — test by pressing the test button. t Float-type low water cut-oﬀ — blowdown and test by opening its blowdown valve. %VERY MONTHS t Inspect boiler piping (oil, gas and water). t Operate relief valve (see label on valve for instructions). %ND OF SEASON t Shut boiler down (unless boiler is used for domestic water or is required for other purposes). t NOTE — For long-term boiler shutdown, contact a qualiﬁed boiler service technician to shutdown the boiler following the procedure in this manual. 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. Maintenance and troubleshooting LOOSE lTTING CLOTHING GLOVES AND EYE PROTECTION N Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust. N Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal. N Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thor- oughly. NIOSH stated First Aid. N Eye: Irrigate immediately. N Breathing: Fresh air. REMOVAL OR INSTALLATION OF FIBERGLASS WOOL: This product contains ﬁberglass jacket insulation and ceramic ﬁber materials in jacket insulation, burner front plate insulation and cleanout plate gaskets. Airborne ﬁbers from these materials have been listed by the State of California as a possible cause of cancer through inhalation. N Avoid breathing dust and contact with skin and eyes. s 5SE .)/3( CERTIlED DUST RESPIRATOR . 4HIS TYPE OF RESPIRATOR IS BASED ON THE /3(! requirements for ﬁberglass wool at the time this document was written. Other types of respira- tors may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this web site. s 7EAR LONG SLEEVED LOOSE lTTING CLOTHING GLOVES AND EYE PROTECTION N Operations such as sawing, blowing, tear out, and spraying may generate airborne ﬁber concentra- tion requiring additional protection. N Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thor- oughly. NIOSH stated First Aid. N Eye: Irrigate immediately. N Breathing: Fresh air. 9. Remove skim piping. 10. Re-insert plug at boiler skim tapping. 11. Close drain cock. 12. Fill with fresh water to normal water line. 13. Start burner and steam for 15 minutes to remove dissolved gases. 14. Stop burner. 15. Check traps and air vents for proper operation. Check boiler for gas-tight seal: Boiler must be sealed gas-tight to prevent possible flue gas leakage and carbon monoxide emissions, resulting in severe personal injury or death. 1. Remove boiler jacket side and top panels. The boiler contains ceramic ﬁber and ﬁberglass materials. Use care when han- dling these materials per instructions on page 38 of this manual. Failure to comply could result in severe personal injury. 2. Start burner. Observe all sealing points and chalk mark any not gas-tight. 3. To seal all chalk-marked areas: a. Use silicone sealant on section ﬂueways. b. Check gaskets and sealing rope placement. 4. Reinstall all jacket panels. swing joints with nipples and elbows several inches long on both suction and return line. Locate close to tank. 13. Install manual shut-off valve in suction line piping near burner and where piping enters building from outside tank. 14. Pitch suction line piping toward fuel tank. 15. Provide tee and plug at highest point in suction line to release air from suction line and aid in priming. &IGURE Gas supply piping vary with each installation. 3. Starting on lowest ﬂoor, open air vents one at a time until water squirts out. Close vent. Repeat with remaining vents. 4. Reﬁll boiler to correct pressure. To ﬁll steam boilers 1. Do not ﬁll (except for leakage test) until boiler is ready to be ﬁred. 2. Fill to normal waterline, halfway up gauge glass. 3. Recommend boiler water pH 7.0 to 8.5. (inches) Boiler ﬂue collar dimensions Balanced (inches) draft (note 4) Forced draft (note 3) 894 18 (note 1) 14 (note 1) 20 round, ﬂanged 994 21 (note 1) 14 (note 1) 20 round, ﬂanged 1094 21 (note 1) 16 (note 1) 20 round, ﬂanged 1194 21 (note 1) 16 (note 1) 20 round, ﬂanged 1294 21 (note 1) 16 (note 1) 20 round, ﬂanged 1394 24 (note 1) 18 (note 1) 20 round, ﬂanged 1494 24 (note 1) 18 (note 1) 20 round, ﬂanged 1594 24 (note 1) 18 (note 1) 20 round, ﬂanged 1694 24 (note 1) 18 (note 1) 20 round, ﬂanged 1794 24 (note 1) 20 20 round, ﬂanged 1894 27 (note 1) 20 20 round, ﬂanged 1994 27 (note 1) 20 20 round, ﬂanged 2094 27 (note 1) 20 20 round, ﬂanged 2194 27 (note 1) 20 20 round, ﬂanged 2294 27 (note 2) 22 20 round, ﬂanged (note 2) 2394 30 (note 2) 22 20 round, ﬂanged (note 2) 2494 30 (note 2) 22 20 round, ﬂanged (note 2) 2594 30 (note 2) 22 20 round, ﬂanged (note 2) .OTE Boiler is supplied with a counterﬂange that must be welded to a 20-inch diameter x 6-inch minimum length adapter. The breeching can then be reduced or increased to the size listed above. .OTE Boiler is supplied with a ﬂanged adapter, 22-inch diameter, for connection to 22-inch diameter breeching. Breeching size can be increased after the adapter if required for the application. .OTE Forced draft — Boiler, breeching and stub vent operate at positive pressure. Entire system must be gas-tight to prevent leaks. Stub vent height must be limited to prevent negative draft with 3-foot minimum stub vent height above roof, 15-foot minimum overall height. See Figure 41 and Figure 42. .OTE Balanced draft — Boiler operates with positive pressure overﬁre. Chimney may provide excess draft which may require a barometric draft control installed and set to provide minimum draft to maintain 0.1" positive pressure at ﬂue collar. Minimum chimney height above roof is 3 feet. Minimum overall height is 20 feet. For other vent heights, use ASHRAE Guide for sizing. See Figure 40 and Figure 42. ¼" .ONE — ½" ¼" 94 (Note 3) 2" .ONE — 2" ¼" 2" ¼" 2" (894 to 1594 only) n OR n 3 (all sizes) ¼" 3 (Note 3) 1"to 1¼" .ONE — Notes: 1. Other manufacturers' controls providing similar functions may be used if properly located and selected. 2. Use low water cut-off function only. Pump controller function must only be handled by the primary control. 3. When pump control is used with feedwater tank, install pump control on boiler and make-up water feeder on tank. Use separate low water cutoff on boiler when back-up is needed. Do not install combination low water cutoff and feeder as back-up control on boiler. Feeder will operate before pump control operates. &IGURE Water level control locations (see Figure 37) Normal water line is at the center of the gauge glass. R1 Skim tapping 4 R2 Steam pressure relief valve 4 3 Steam pressure gauge — or — Pressure controls (limit, operating, etc.) ¾ 3 Pressure controls (limit, operating, etc.) ¾ 4 OR 4 Pressure controls (limit, operating, etc.) 1¼ 4 OR 4 Steam pressure gauge — or — Pressure controls (limit, operating, etc.) 1¼ 5 OR 5 Steam pressure relief valve — Install relief valve in one tapping and plug the other 2 6 OR 6 Steam pressure relief valve — or — Skim tapping 4 7 OR 7 Steam pressure gauge — or — Pressure controls (limit, operating, etc.) ¾ 7 OR 7 Pressure controls (limit, operating, etc.) ¾ 8 8 PLUG these tappings — not used 1¼ 8 8 PLUG these tappings — not used 1¼ 9 9 Try cocks 3⁄8 : OR : Cleanout tappings — Front section — Install 3-inch close nipple and 3-inch cap in each cleanout tapping 3 : OR : Cleanout or drain tappings — Rear section — Install drain valve in one tapping; install 2½" x 2" reducing nipple and 2" cap in the other 2½ Low limit temperature control (when using tankless heaters) — locate in control tapping on one of the tankless heaters — Air vent piping to compression tank 1¼ 5 5 Pressure relief valve(s): 894–2094: Install relief valve in one tapping and plug the other tapping 2194–2594: Install a relief valve in each tapping (2 relief valves required on these boilers) 2 V1 Temperature control or limit 4 7 OR 7 Temperature control or limit — or — P/T gauge or temperature gauge ¾ 8 OR 8 Temperature control or limit — or — Air vent piping to compression tank 1¼ 9 9 PLUG this tapping — unless needed for a control 3⁄8 : OR : Cleanout tappings — Front section — Install 3-inch close nipple and 3-inch cap in each cleanout tapping 3 : OR : Cleanout or drain tappings — Rear section — Install drain valve in one tapping; install 2½" x 2" reducing nipple and 2" cap in the other 2½ Low limit control (when using tankless heaters) — locate in control tapping on one of the tankless heaters — NOTES )NLET AND OUTLET TAPPINGS 590-921-910 9 11 ¾" Note 1 GPM based on 40–140°F DHW with boiler water at 200°F Note 2 Based on continuous draw with no recovery period &IGURE Tankless Heater Piping Pipe tankless heaters 8. Hand-tighten 4 nuts to secure access door. &IGURE Front section block assembly components K20 K22 K24 M &IGURE Rear section block assembly components K40 D K41 and four brackets on the back section. Install front and rear jacket panels 1. Place the right front jacket panel against the right side of the front section, with the jacket ﬂanges over the mounting brackets. 2. Secure with a #10 x ½" type A sheet metal screw on the right side and top into the two brackets. 3. Set the left front jacket panel in place and secure in the same way. Make sure the jacket panels have had all necessary knockouts removed and all holes are properly aligned. 4. Secure the left and right front panels together with the #10 x ½" screws provided. 5. Use the same procedure to install the jacket rear panels. Start with the left side panel, then the right side panel. Install brackets and side panel splice channels (1094–2594) 1. Side panel brackets are not required for boiler sizes 894 and 994. Skip to the next section. See the following for 1094 through 2594 boilers. 2. See Figure 27. 3. Larger boilers use multiple side panels, requiring splice chan- nels as shown in Figure 27. a. Each splice channel is attached to the brackets with four screws as shown. b. Boilers 1094 through 1894 require one set of splice chan- nels. Boilers 1994 through 2594 require two sets. 4. The brackets that secure the splice channels mount to the tie rod lugs as shown in Figure 27, using 5/8"-11 N.C. hex nuts supplied. a. Locate the brackets on the sections speciﬁed in Fig- ure 26. b. Brackets must be oriented as shown, with their edges point at one another. DO NOT loosen the existing tie 1 inch. c. Secure assembly to plate with 1⁄4" x 3⁄4" ﬂat-head machine screws. Cleanout and inspection tappings 1. If cleanout and inspection tappings were ordered, use 1½" brass coun- tersunk plugs to plug openings. 2. If using "TI" sections, install tankless or storage heaters and gaskets, or heater plates and gaskets. Use 3⁄8" cap screws. Remove jacket parts from cartons and inspect 1. Locate jacket cartons. 2. Remove jacket parts from cartons as needed. Leave in cartons as long as possible to avoid damage. 3. Inspect all parts before installing. 4. Jacket parts are in the boxes listed in Figure 25, page 21. Prepare jacket panels for use 1. Determine from the control tapping table (Figure 10, page 12 or Fig- ure 11, page 13) which of the knockout openings in the jacket panels will be used. 2. To remove a knockout disc, bend one side inward until it can be grasped with a pair of pliers; then, bend the disc back and forth until it breaks loose. The JACKET SIDE PANELS are reversible and can be placed on either the left or right side of the boiler. If the boiler was ordered with tankless coils (supplied with intermediate sec- tions with tankless coil openings), the jacket side panels with tankless coil knockouts must be properly positioned on the right-hand side of the boiler ONLY. 1594 4,070 489 147 294 441 588 16.5 1694 4,360 524 158 316 474 632 17.5 1794 4,650 559 168 336 504 672 19.0 1894 4,940 594 179 358 537 716 20.0 1994 5,230 628 189 378 567 756 21.0 2094 5,520 663 199 398 597 796 22 0 2194 5,810 698 210 420 630 840 22.0 2294 6,100 732 220 440 660 880 24.0 2394 6,390 767 231 462 693 924 26.0 2494 6.680 802 241 482 723 964 27.0 2594 6,970 837 252 504 756 1,008 28.0 Note 1 — Maximum time to when condensate returns to boiler — the longer the time for condensate to return, the larger the receiver must be. "TUH 4EMPERATURE RISE X c. Calculate only secondary (boiler) piping circuit resistance. Al- low for head loss through the boiler equal to three 90 degree elbows of secondary pipe size. d. Operate each boiler and its pump with a Weil-McLain boiler control panel. e. Size secondary (boiler) circuit piping using the ﬂow rate ranges given in Figure 15. B Primary pump GPM and head calculation should not include secondary boiler circuits. Primary pump can operate continuously during heating season. C Connection to primary circuit — Space 12" maximum or as close as practical. D Check valve. E Hand valve. &IGURE By-pass piping for return water less than 140°F "Y PASS CIRCULATOR SIZING 1. Size system circulator as required. Determine GPM and head requirements. 2. Provide a by-pass circulator for EACH boiler. The ﬂow rate for each by-pass circulator will be: Flow = ¼ x (System circulator GPM) ÷ (# of boilers) 3. All circulators must run at the same time. 4. Example: For a 1,000,000 Btuh single boiler, with system temperature drop of 20°F: s System GPM = 1,000,000 ÷ 20 ÷ 500 = 100 GPM s By-pass GPM = ¼ x 100 GPM = 25 GPM s Determine by-pass circuit head loss for pipe size and ﬁttings used. 5. In most applications, a standard booster pump should be adequate. &IGURE Multiple water boiler piping '0- 3UPPLY PIPE SIZE A 2ETURN PIPE SIZE B UP TO 3" 3" n 4" 4" n 5" 5" n 6" 6" n 8" 8" n 10" 10" Note 1 High temperature rise through boiler is permissible when boiler piping connections are sized per this table. Intermittent ﬂow at high velocities may damage any boiler. Prepare boiler and test: 1. See Figure 10 (water boilers) or Figure 11 (steam boilers) for tapping locations. 2. Install water pressure gauge — FOR TEST ONLY. Be sure gauge can handle test pressure — see step 8 for required test pres- sure. Gauge range should be at least 1.5 times the test pres- sure. Install the pressure test gauge in the tapping speciﬁed in Figure 10 (water boilers) or Figure 11 (steam boilers). 3. Install an air vent in an upper tapping. 4. On front section: Install 3" close nipples and caps in washout tappings. 5. On rear section: Install drain valve (furnished by installer) in one of the washout tappings. (Verify drain valve size per Figure 15, page 15.) Install 2" x 21⁄2" nipple and cap in the other washout tapping. 6. Plug or use blind ﬂanges on remaining tappings. Do not pressure test with any control installed. Damage to control can occur due to overpres- sure. 7. Fill the boiler with water. Vent all air. 8. Pressure test at least 10 minutes at a pressure not less than the following: a. 3TEAM boiler: "ETWEEN AND PSIG. b. 7ATER boiler: TIMES MAXIMUM ALLOWABLE WORKING PRESSURE (MAWP) stamped on the boiler nameplate, located on boiler jacket front panel. Do not exceed above test pressures by more than 10 psig. Do not leave boiler unattended. Cold water ﬁll could expand and cause excessive pressure, result- ing in severe personal injury, death or substantial property damage. 9. Check for maintained gauge pressure and leaks. Repair if found. Leaks must be repaired at once. Failure to do so can damage boiler, resulting in substantial property damage. Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to system components can result, causing substantial property damage. 10. Drain boiler and remove air vent, boiler drain and gauge. 11. Remove plugs from tappings that will be used for controls and accessories. monoxide emissions, resulting in severe per- sonal injury or death. 7. Install remaining intermediate sections and front section using the same procedure. If using tankless heater (TI) sections s Install tankless heaters and gaskets or heater cover plates and gaskets. s Use 3⁄8" x 3⁄4"studs, washers and nuts. Assembling the block (continued) NEXT TO OR UNDER SEAL ING RING. &IGURE Sealing rope installation as shown in Figure 1, page 4. 6. Level boiler. Shim under legs if necessary. 7. Cut off cables. Cables are not intended for long-term usage. Cables may corrode inside boiler, weakening their lifting strength. Failure to remove cables can result in severe personal injury, death or substantial property damage. 8. Inspect block assembly for disjointed sections. a. Check inside section assembly for any light passing through unsealed areas. b. Mark all unsealed areas. c. At unsealed areas, check for: s Damaged gaskets. s Sealing rope not in place. s Loose bolts or nuts. d. Correct all conditions and repeat step b. If unsealed areas still exist, contact your Weil-McLain distributor or sales ofﬁce before continuing installation. 9. Check gas-tight seal of ﬂue collector hood and cleanout plates. Gas tight seal must be maintained to prevent possible ﬂue gas leakage and carbon monoxide emissions, resulting in severe personal injury or death. 10. Proceed to "Perform hydrostatic pressure test," page 11. Non-motorized louvers and grilles shall be ﬁxed in the open position. -INIMUM SCREEN MESH SIZE Screens shall not be smaller than ¼ inch mesh. -OTORIZED LOUVERS Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignition and during main burner operation. Means shall be proved to prevent the main burner from igniting should the louver fail to open during burner startup, and to shut down the main burner if the louvers close during burner operation. Two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclo- sure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that (boiler sections ﬂush with one end of foundation, 4 inches from the other end) "OILER MODEL NUMBER ,ENGTH L1 (inches) 894 55 994 61 1094 67 1194 73 1294 79 1394 85 1494 91 1594 97 1694 103 1794 109 1894 115 1994 121 2094 127 2194 133 2294 139 2394 145 2494 151 2594 157 (EIGHT H (inches) Gun-type burner: 2 inches min. Horizontal rotary or air atomizing burner: 7 inches min. Consult burner manufacturer for required clearances if burner is not supplied by Weil-McLain. N Consult your propane supplier regard- ing installation of a gas leak detector. There are some products on the market intended for this purpose. Your sup- plier may be able to suggest an appro- priate device. Read before proceeding £ , Model Number 1 Gas LHO LHL MOD LHO LHL MOD LHO LHL MOD LHO LHL MOD 894-1394 RM7895C RM7895C RM7840L RM7895C RM7895C RM7840L RM7895C RM7895C RM7840L RM7895C RM7895C RM7840L 1494-1894 RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L 1994-2594 -- -- RM7840L -- -- RM7840L -- -- RM7840L -- -- RM7840L Boiler Model Number 1 - £ , Light oil LHO LHL MOD LHO LHL MOD LHO LHL MOD LHO LHL MOD 894-994 R8184G R8184G RM7840L R8184G R8184G RM7840L RM7895A RM7895A RM7840L RM7895A RM7895A RM7840L 1094-1194 RM7896A RM7896A RM7840L RM7896A RM7896A RM7840L RM7896A RM7896A RM7840L RM7896A RM7896A RM7840L 1294-1894 RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L RM7840L 1994-2594 -- -- RM7840L -- -- RM7840L -- -- RM7840L -- -- RM7840L Boiler Model Number 1 - £ , o 300 298 255 50-100 22R323D 135 Direct 3450 -- 1694 4.83 2.82 7.65 28.00 3/8 3/8 28.00 Monarch BPS 80 o 300 195 120 20-50 22R323D 135 Remote 3450 -- 1794 5.50 2.98 8.48 28.00 3/8 3/8 28.00 Monarch BPS 80 o 300 202 137 40-80 22R323D 135 Remote 3450 -- 1894 6.22 3.29 9.51 28.00 3/8 3/8 28.00 Monarch BPS 80 o 300 223 153 40-80 22R323D 135 Remote 3450 -- 1994 6.96 3.70 10.66 28.00 3/8 3/8 28.00 Monarch BPS 80 o 300 256 179 40-95 22R323D 135 Remote 3450 -- 2094 5.43 4.06 9.49 28.00 3/8 3/8 28.00 Monarch BPS 80 o 300 279 199 40-100 22R323D 135 Remote 3450 -- 2194 6.03 3.57 9.60 28.00 3/8 3/8 30.00 Monarch BPS 80 o 300 282 210 40-95 2VO26C 250 Remote 1725 1 2294 6.65 3.83 10.48 28.00 3/8 3/8 35.00 Monarch BPS 80 o 300 237 153 20-60 2VO26C 250 Remote 1725 1 2394 5.29 4.19 9.48 28.00 3/8 3/8 35.00 Monarch BPS 80 o 300 265 172 25-75 2VO26C 250 Remote 1725 1 2494 5.79 4.55 10.34 28.00 3/8 3/8 35.00 Monarch BPS 80 o 300 285 187 25-80 2VO26C 250 Remote 1725 1 2594 6.31 4.91 11.22 28.00 3/8 3/8 40.00 Monarch BPS 80 o 300 232 172 0-40 2VO26C 250 Remote 1725 1 ** Gas pressure shown are for standard gas train arrangement. ▲ Primary manufacturer. For alternate nozzles, contact Power-Flame. Fuel Unit Data Type Gear GPH Mounting Speed RPM Motor H.P. Boiler Model Number Oil Nozzle (One Per Unit) GPH @ 100 PSIG Brand ▲ Type Spray Angle Pressure Drop Thru Gas Train Inches W.C. High Fire Pump Capacity Oil Pressures PSIG Approximate Return Gas Pressure Required at Inlet Gas Control Inches W.C.** Initial Low Fire Damper Settings Inches Gas Test Tee Pressure Inches W.C. Standard Combustion Control Burner Motor 3450 RPM H.P. Standard BoilerSystems Control Model Number Burner Input Positive Pressure in Firebox Inches W.C. Standard gas control components and sizes in inches Boiler Model Number Manual Hand Valve Low Gas Pressure Switch Gas Pressure Regulator Solenoid Operating Gas Valve Motorized Operating Gas Valve Motorized Operating Gas Valve w/Proof of Closure Safety Gas Valve Manual Checking Gas Valve High Gas Pressure Switch 894-1494 2 Standard 2 2 2 Optional 2 2 Standard 1594 2 Standard 2 2 -- 2 2 2 Standard 1694-1994 2 Standard 2 1/2 2 -- 2 2 2 1/2 Standard 2094-2294 2 1/2 Standard 2 1/2 2 1/2 -- 2 1/2 2 1/2 2 1/2 Standard 2394-2594 3 Standard 3 3 -- 3 3 3 Standard