Weil-McLain 1094, Manual

Page 1: ...before installing Follow all instructions in proper order Failure to comply could result in severe personal injury death or substantial property damage 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...

Page 2: ...ries CP 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 p...

Page 3: ...Control tapping locations steam boilers 13 Connect water boiler piping 14 Connect steam boiler piping 16 Complete block assembly install jacket 20 Pipe tankless heaters 25 Install water boiler controls 26 Install steam boiler controls 28 Connect breeching and venting systems 31 Install fuel piping 34 Make final adjustments 35 Handling ceramic fiber and fiberglass materials 36 Maintenance and troubles...

Page 4: ...2 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 Right side for cleaning and for tankless heater insertion re moval 44 inches Rear for breeching 50 inches Allow sufficient space on remaining sides for cleaning servicing and burner in...

Page 5: ...um volume must be calculated as specified in the standard Inside 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 Combining 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 10...

Page 6: ...all 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 ...

Page 7: ...ed 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 Using crane attach free end of cables to eye of crane 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 x 3 steel plates on floor or foundation spaced 51 inches apart as ...

Page 8: ...he 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 section is placed A gas tight seal must be maintained to prevent possibility of fluegasl...

Page 9: ...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 ca...

Page 10: ... 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 th...

Page 11: ...kets on top of SI sections Supply outlet installed close to boiler front should have 1 tapping facing front Use 5 8 x 3 studs nuts and washers 3 Secure 6 NPT return opening counter flange and gasket to back section using x 2 hex head cap screws and washers 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 o...

Page 12: ...094 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 W1 or W2 Temperature control or limit or P T gauge or temperature gauge X1 or X2 Temperature control or limit or Air vent piping to compression tank 1 Y1 Y2 PLUG this tapping unless needed for a control 3 8...

Page 13: ...essure gauge or Pressure controls limit operating etc 1 U1 or U2 Steam pressure relief valve Install relief valve in one tapping and plug the other 2 V1 or V2 Steam pressure relief valve or Skim tapping 4 W1 or W2 Steam pressure gauge or Pressure controls limit operating etc W3 or W4 Pressure controls limit operating etc X1 X2 PLUG these tappings not used 1 X3 X4 PLUG these tappings not used 1 Y1 ...

Page 14: ... 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 m...

Page 15: ...gh limit temp Return water temp b GPM Boiler Gross Output Btuh Temperature rise x 500 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 ...

Page 16: ... condensate to return the larger the receiver must be Figure 20 Condensate receiver capacity requirements 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 863 4 from bottom of section 3 When using cond...

Page 17: ... water Hartford 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 Pipe Dimensions Model Riser A ...

Page 18: ...tion of the header 3 Steam supply must be located between last riser connection and equalizer elbow 4 Equalizer elbow full size or reducing 5 Equalizer pipe 6 Close nipple at Hartford loop tee to reduce water hammer potential 7 Condensate return line gravity or pumped 8 Pipe to provide 4 inches between water line and top of Hartford loop return nipple 9 Boiler water line all automatic water level ...

Page 19: ...ps 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 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 pa...

Page 20: ...d and save c Repeat for remaining five studs d Apply 1 8 continuous bead of rope adhesive in groove around opening e Position sealing rope in groove Overlap ends about 2 inches f Install burner mounting plate with observation port at top of plate Use 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...

Page 21: ...ton quantities Boiler model End panel cartons Splice channel cartons Side panel cartons Top panel cartons 94 EP 94 SC A B C D E A B C D E CO EO 8 1 1 1 9 1 1 1 10 1 1 2 2 11 1 1 1 1 1 1 12 1 1 1 1 1 1 13 1 1 1 1 1 1 14 1 1 2 2 15 1 1 1 1 1 1 16 1 1 1 1 1 1 17 1 1 1 1 1 1 18 1 1 2 2 19 1 2 1 2 1 2 20 1 2 1 2 1 2 21 Steam 1 2 3 1 2 21 Water 1 2 3 2 1 22 Steam 1 2 2 1 1 2 22 Water 1 2 2 1 1 1 1 23 St...

Page 22: ...set 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 and four brackets o...

Page 23: ...n Start Up Maintenance Parts 23 Part No 550 110 275 1018 Figure 27 Installing jacket support brackets support channels and corners piping and other components omitted for clarity Complete block assembly install jacket continued ...

Page 24: ...uds 6 Apply1 8 continuousbeadof ropeadhesiveingroovearoundplates 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 h...

Page 25: ...ize 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 Hot water can scald ConsumerProductSafetyCommissionandsome states ...

Page 26: ... the installer field installed to comply with currentASME Boiler and Pressure Vessel Code Section IV 4 Dual limit control settings a Low set according to design requirements b High at least 20 higher than low limit 240 F maximum 5 Install optional controls per control manufacturer s instructions Figure 32 Model 94 water boiler control tappings Item Function Size Inches NPT J1 Temperature control or...

Page 27: ...enance Parts 27 Part No 550 110 275 1018 Install water boiler controls continued Figure 33 Model 94 water boiler control tappings Controls and fittings must not obstruct cleanout openings or pre vent required access to the boiler or components ...

Page 28: ...l suitable for 375 F threaded one end only Install drain pan elbow to drain condensate 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 Figure 34 Model 94 steam boiler control tappings Item Function Size Inches NPT J1 J5 Gauge glass J2 PLUG this tapping not used ...

Page 29: ...access to the boiler or components Figure 36 Steam control siphon and fittings Manifold component sizing Check local codes for sizing and cleanout requirements Item Description Size inches 894 2094 2194 2594 a Nipple x as needed x as needed b Plug c Reducing tee x x x x d Cross e Nipple x as needed x as needed f Nipple x as needed x as needed g Nipple x as needed x as needed h Nipple x CLOSE x 4 k ...

Page 30: ...1 S 2 all sizes 51 2 51 S 2 Note 3 1 to 1 None 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 c...

Page 31: ...o 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 Figure 39 Minimum breeching diameter Boiler model AHRI vent or liner diame...

Page 32: ... 110 275 1018 Connect breeching and venting systems Figure 40 Conventional chimney balanced draft with barometric draft control when required single boiler Figure 41 Stub vent forced draft single boiler Figure 42 Conventional chimney balanced draft with barometric draft control when required multiple boilers ...

Page 33: ...ealing com pounds in boiler system Severe damage to system com ponents 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 softene...

Page 34: ...ilure 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 fi...

Page 35: ...ult 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 com ponents can result causing substantial property damage 1 Provide 4 skim piping from tapping to floor drain 2 Rais...

Page 36: ...chamber lining or base insulation from the boiler and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thor oughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air REMOVAL OR INSTALLATION OF FIBERGLASS WOOL This product contains fiberglass jacket insulation and ceramic fiber materials in jacket insulat...

Page 37: ...e 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 Verify operation of boiler and all controls If operational problems are observed correct the problems and re start Review Review with owner Daily Inspect boiler area must be free of combustible materials gasoline and other flam...

Page 38: ...res or boiler patent medicines on the market under various trade names as serious damage to the boiler personnel 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 Electrical shock...

Page 39: ...er 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 proper operation but should be free of sludge or sediment Long term boil...

Page 40: ...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 boile...

Page 41: ... 9 84 0 81 5 83 0 80 5 85 9 83 3 85 4 82 9 118 36 2945 0 650 20 607 1 2194 50 0 7216 5809 6028 18792 4510 5241 173 6 84 0 81 5 83 0 80 5 86 1 83 5 85 6 83 1 124 44 3120 0 750 20 634 8 2294 53 0 7649 6157 6404 19919 4781 5568 182 2 84 0 81 5 83 0 80 5 86 3 83 7 85 8 83 3 130 52 3255 0 850 20 662 6 2394 55 0 7938 6390 6655 20672 4961 5787 190 9 84 1 81 5 83 0 80 5 86 4 83 8 86 0 83 4 136 60 3410 0 9...

Page 42: ...17 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 Supply return tappings All 6 are tapped All 8 and 10 are flanged Burner len...

Page 43: ...Boiler manual Installation Start Up Maintenance Parts 43 Part No 550 110 275 1018 Dimensions continued Figure 46 Dimensions INCHES see lettered dimensions on opposite page ...

Page 44: ...r cleanout with tapping 330 060 700 Stud 13 x 4 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 stud threads into mounting stud casting 9256 340 004 635 Mounting stud 13 x 21 8 long 560 340 560 K22 Hinge for cleanout door casting 9254 330 060 500 K24 Hinge plate for clea...

Page 45: ...Boiler manual Installation Start Up Maintenance Parts 45 Part No 550 110 275 1018 Parts continued Figure 47 Block assembly parts ...

Page 46: ...ef Valve 1 inlet x 1 side outlet Brass 30 PSIG Watts 740 511 546 935 1 1 1 ASME Pressure Relief Valve 1 inlet by 2 side outlet Brass 30 PSIG Watts 740 511 546 940 1 1 2 ASME Pressure Relief Valve 2 inlet by 2 Side outlet Brass 30 PSIG Watts 740 511 546 945 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Combination Pressure Temperature gauge 0 55 PSIG 60 260 F 0 148 ft Back Connection NPT ENFM 4104 3 25 510 218 065...

Page 47: ...510 218 100 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 note Water gage glass cocks set NPT Male inlet Conbraco 21 205 03W 510 218 145 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 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 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Honeywell PA404A 1009 6 Steam safety ...

Page 48: ...Weil McLain 94 Series 3 Water and steam boilers for Gas Light Oil Gas Light Oil Fired Burners 48 Part No 550 110 275 1018 ...