Weil-McLain 78 User Manual

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78 78

Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners

Boiler Manual

Installation

Maintenance

Start-Up

Parts

Installer: Leave all documentation received with boiler and burner with unit for future reference.

User: Boiler and burner must be installed and serviced by a qualified service technician.

This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in severe personal injury, death or substantial property damage.

Part No. 550-141-705/0600

Weil-McLain 78 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners

Contents

1.

Before Installing Boiler..............................................................

page 3

2.

Set Packaged Boiler or Block Assembly in Place................

page 5

3.

Assemble Block..........................................................................

page 6

4.

Perform Hydrostatic Pressure Test.......................................

page 12

5.

Connect Water Boiler Piping..................................................

page 13

6.

Connect Steam Boiler Piping.................................................

page 15

7.

Install Jacket .............................................................................

page 19

8.

Pipe Tankless Heaters.............................................................

page 19

9.

Install Water Boiler Controls ..................................................

page 20

10.

Install Steam Boiler Controls .................................................

page 21

11.

Connect Breeching and Venting Systems...........................

page 23

12.

Install Burner.............................................................................

page 24

13.

Wiring and Fuel Piping............................................................

page 24

14.

Make Final Adjustments..........................................................

page 25

15.

Data and Dimensions ..............................................................

page 27

16.

Parts............................................................................................

page 29

17.

Ratings .......................................................................................

page 31

Warranty......................................................................................

Back Cover

When Calling or Writing about the Boiler

Please have model and series from boiler rating label and CP number(s) from boiler jacket or controls.

Hazard Definitions

The following defined terms 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 installation, operation or maintenance that are important but not related to personal injury.

Read all instructions before installing. Failure to follow all instructions in proper order can cause severe personal injury, death or substantial property damage.

2

Do not use petroleum-based cleaning or sealing components in boiler system. Severe damage to system components can result, causing substantial propety damage.

Part No. 550-141-705

• Installation

• Start-Up

• Maintenance

• Parts

1a Before Installing Boiler

Installation must comply with:

State, provincial and local plumbing, heating and electrical codes.

Regulations of serving utilities.

National codes where applicable.

Before selecting boiler location:

Check for nearby connections to:

fuel supply

electrical power

system water or steam piping

venting systems - see page 23

combustion and ventilation air supply - see “Provide combustion and ventilation air supply openings” below

Check area around boiler for and 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 combustion and ventilation air openings:

Do not install an exhaust fan in boiler room. 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.

Grating – Min. 12" above avg. snowline

GRADE

Areaway

Note:

Size of areaway and grating to be equal to or greater than total louver area.

Louver

Boiler room floor

Opening sizes must comply with state, provincial or local codes. In their absence, use the following when boiler is in a confined room:

Provide two permanent openings in boiler room - one within 12 inches of ceiling, one within 12 inches of floor. Minimum dimension of each opening - 3 inches.

-When all air is taken from within building, each opening should be at least one square inch/1,000 Btuh boiler input and freely connect with areas having adequate infiltration from outside

-When all air is taken from outdoors, each opening should connect directly or by ducts from outdoors or crawl or attic spaces that freely connect with outdoors and sized as listed below:

-through outside wall or vertical ducts - at least one square inch/4,000 Btuh boiler input

-through horizontal ducts - at least one square inch/2,000 Btuh boiler input

-where ducts are used, they should be same cross-sectional area as free area of openings they are connected to

-compensate for louver, grille or screen blockage when calculating free air openings. Refer to their manufacturer’s instructions for size. If unknown, use:

-wood louvers - 20-25% free air

-metal louvers or grilles - 60-75% free air

-screens - not less than 1/4 inch mesh Lock louvers in open position, or interlock with equipment to prove open before boiler operation.

Louver – Min. 12" above avg. snowline

Note: GRADE Duct size

equal to total louver area

Boiler room floor

Figure 1 Combustion and Ventilation Air

Figure 2 Combustion and Ventilation Air

Openings Boiler Room Below Grade

Openings Boiler Room Partially or Completely

Part No. 550-141-705

Above Grade

3

Weil-McLain 78 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners

1b Before Installing Boiler

Provide clearances for servicing around boiler:

Back, for breeching - 30 inches.

Left side, for cleaning and tankless heater removal - 34 inches

Allow sufficient space on remaining sides for cleaning, servicing and burner installation. See burner literature for length.

Clearance from vent pipe to combustible materials:

-singlewall vent pipe - 18 inches

-doublewall vent pipe - refer to vent pipe manufacturer’s recommendations for vent pipe clearances

Lay a foundation, if needed:

Floor construction and condition must be suitable for weight of boiler when filled with water. See page 31 for boiler weight/water weight.

A level concrete or brick foundation is required when:

A floor could possibly become flooded

Non-level conditions exist

Boiler Foundation Length Table

Boiler

“L”

Boiler

“L”

Model

Inches

Model

Inches

 

 

 

 

378

23

878

58

 

 

 

 

478

30

978

65

 

 

 

 

578

37

1078

72

 

 

 

 

678

44

1178

79

 

 

 

 

778

51

1278

86

 

 

 

 

2" Min.

“L”

30"

Figure 3 Boiler Foundation

4

Part No. 550-141-705

• Installation

• Start-Up

• Maintenance

• Parts

2a Set Packaged Boiler or Block Assembly in Place

For packaged boiler:

1.Remove top jacket panel. Set aside until after boiler is piped.

2.Remove lag screws (2 in front, 2 in rear) from shipping rails.

3.Remove boiler from skid. Cables are already attached to block assembly. See Lifting Weight Chart.

Using crane - hook middle of each cable to eye of crane.

Using hoist - hook middle of each cable to hoist. Raise boiler off skid. Use pipe rollers under skid angles to roll boiler.

4.Place boiler in final position. Center boiler on foundation, if used.

5.Level boiler. Shim under skid angles, if necessary.

6.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.

7.Proceed to “4a: Perform Hydrostatic Pressure Test,” page 12.

For block assembly:

1.Remove lag screws (2 in front, 2 in rear) from shipping rails.

2.Remove boiler from skid. Cables are already attached to block assembly. See Lifting Weight Chart.

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.

3.Place boiler in final position. Center boiler on foundation, if used.

4.Level boiler. Shim under skid angles, if necessary.

5.Cut off cables.

Cables are not intended for longterm 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.

6.Inspect block assembly for disjointed sections. Check gas-tight seal of flue collector hood, flue collar 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.

a.Open damper in flue collar.

b.Check inside section assembly for any light passing through unsealed areas.

c.Mark all unsealed areas.

d.At unsealed areas, check for damaged gaskets, sealing rope not in place, loose bolts or nuts, or missing holddown clips. Correct all conditions and repeat step b. If unsealed areas still exist, contact your Weil-McLain distributor or sales office before continuing installation.

7.Proceed to “4a: Perform Hydrostatic Pressure Test,” page 12.

 

 

 

Lifting Weight Chart

 

 

 

 

 

 

 

 

 

 

 

Packaged

Assembled

 

Packaged

Assembled

 

Boiler

Boiler

Block

Boiler

Boiler

Block

 

Model

Lbs.

Lbs.

Model

Lbs.

Lbs.

 

 

 

 

 

 

 

 

378

1355

1150

878

2650

2325

 

 

 

 

 

 

 

 

478

1615

1385

978

2910

2560

 

578

1875

1620

1078

3165

2795

 

678

2130

1855

1178

3425

3030

 

778

2390

2090

1278

3680

3265

 

 

 

 

 

 

 

Part No. 550-141-705

 

 

 

 

5

Weil-McLain 78 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners

3a Assemble Block

Sections are top heavy. Unbolted sections may fall if not supported, resulting in severe personal injury or death.

Install back refractory blanket:

1. Lay back section on floor with ports face up. 2 Apply water glass as an adhesive to blanket.

3.Press blanket against back target wall as shown in Figure 4.

4.Using knife, cut hole through blanket to expose observation port opening.

Prepare back section:

1.Apply 1/8" continuous bead of sealing rope adhesive in sealing rope grooves. See Figure 4. Do not get any adhesive on machined port surfaces.

2.Place 1/2" sealing rope in groove. Around curves, grasp at 1" intervals and push together. Do not stretch.

Do not pre-cut rope. Gas tight seal must be maintained to prevent possibility of flue gas leakage and carbon monoxide emissions, causing severe personal injury or death.

3.Remove any grit from port machined surfaces with clean rag.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to system components can result, causing substantial property damage.

4.Place 7-1/2" and 3-1/2" sealing rings in appropriate port openings. See Figure 4. If sealing ring slips out of groove, stretch ring gently for several seconds, then reposition in groove.

 

 

Cut off rope

 

 

even with

 

 

edges

 

Sealing rope

7 1/2"

 

 

 

Sealing

 

 

 

 

 

 

 

 

 

 

 

 

ring

 

Cut off rope

 

 

 

 

even with

 

 

 

 

edge

 

 

 

 

 

 

Sealing

 

 

 

rope

 

 

 

Cut out

 

 

 

observation

 

 

 

port opening

Cut off

 

 

 

 

rope

 

 

Back refractory

even

 

 

 

 

(apply waterglass

with

 

 

 

 

to entire back side)

edge

 

 

 

 

 

 

 

3 1/2” Sealing ring

 

Figure 4

6

Part No. 550-141-705

Weil-McLain 78 User Manual

Weil-McLain 78 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners

3c Assemble Block

Prepare remaining sections:

1.Follow “Prepare intermediate section” for remaining intermediate and front sections:

a.Remove any grit from threads inside tapped holes with clean rag.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to system components can result, causing substantial property damage.

b.Install TI (Tankless Intermediate) and SI (Supply Intermediate) sections (when used) in order shown in “Section Arrangement Table”.

c.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 monoxide emissions, resulting in severe personal injury or death.

Section Arrangement Table

 

 

Maximum

Section Arrangement

Boiler

No. of

(all heaters must be

Model

Heaters

on left side of boiler)

 

 

 

378 W&S

1

F-TI-B

 

 

 

478 W&S

1

F-TI-I-B

578 W&S

2

F-TI-I-TI-B

 

 

 

678 W&S

2

F-TI-I-TI-I-B

778 W&S

2

F-TI-I-TI-I-I-B

 

 

 

878 W&S

3

F-TI-I-TI-I-I-TI-B

978 W&S

3

F-TI-I-TI-I-TI-I-I-B

 

 

 

 

1078

W

3

F-TI-I-TI-I-I-TI-I-I-B

1078

S

3

F-TI-I-TI-SI-I-TI-I-I-B

 

 

 

1178 W

4

F-TI-I-TI-I-I-I-TI-I-TI-B

1178 S

4

F-TI-I-TI-I-SI-I-TI-I-TI-B

 

 

 

 

1278

W

4

F-TI-I-TI-I-I-I-I-TI-I-TI-B

 

 

 

 

1278

S

4

F-TI-I-TI-I-SI-I-I-TI-I-TI-B

 

 

 

 

If you would like to pressure-test block assembly now, proceed to page 12.

d.Make sure bottom refractory blanket has been installed per instructions on page 7.

Install burner mounting plate on front section:

1.Install four 1/2" x 4-3/4" studs to secure burner mounting plate to section:

a.Thread and lock together two nuts on rounded end of stud. Thread flat end of stud into one of four holes located around opening.

b.Remove nuts.

c.Repeat steps a and b for remaining studs.

2.Install burner mounting plate:

a.Apply 1/8" continuous bead of sealing rope adhesive in groove around opening in section.

b.Position 1/2" sealing rope in groove. Overlap ends at least one inch.

c.Install burner mounting plate. Use 1/2" washers and nuts.

Install observation port assemblies on front and back sections:

1.Install front observation port assembly:

a.Apply 1/8" continuous bead of sealing rope adhesive in groove on observation port.

b.Position 3/8" sealing rope in groove. Overlap ends at least one inch.

c.Secure assembly to section. Use 5/16-18 x 3/4" slotted head screws.

2.Repeat above steps for back observation port assembly.

If using TI sections:

Install tankless heaters and gaskets or heater cover plates and gaskets. Use 3/8" x 3/4" studs and nuts.

W=Water, S=Steam, F=Front, TI=Tankless Intermediate, I=Intermediate, SI=Supply Intermediate for steam boilers, B=Back. “I” sections can be substituted for “TI” sections.

8

Part No. 550-141-705

Weil-McLain 78 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners

3e Assemble Block

Prepare flue collector hood assembly:

Make sure gaskets are intact, not torn or otherwise damaged. These conditions can cause possible flue gas leakage and carbon monoxide emissions, resulting in severe personal injury or death.

1.Stand one collector hood module on end.

2.Wipe all flanged surfaces with clean rag.

3.Lay gasket on flange. Refer to Figure 8.

4.Place end cap on gasket, aligning flanged surfaces. Secure with six 5/16" x 5/8" flanged bolts and flanged nuts. Tighten to 30 - 35 in.- lbs.

5.For 878 - 1278:

a.Stand remaining hood module on end.

b.Wipe all flanged surfaces with clean rag.

c.Lay gasket on flange.

d.Carefully place open end of first module on top of gasket, aligning flanged surfaces.

e.Secure with six 5/16" x 5/8" flanged bolts and flanged nuts.

6.Attach flat-stitched sealing rope to hood assembly. See Figure 9:

a.Lay hood on floor with flanged side up.

b.Wipe flanged surface with clean rag to remove dirt and oil.

c.Apply double-faced tape to flanged surface.

d.Apply rope to tape beginning on one side of open end of hood, leaving 1/4" extending past edge. Around corners, bend rope, do not cut. Do not stretch rope.

Do not pre-cut rope. Gas-tight seal must be maintained to prevent possible flue gas leakage and carbon monoxide emissions, resulting in severe personal injury or death.

e.Continue around entire flange. At other open end, leave 1/4" rope extending past edge of flange. Cut off excess rope.

Double-faced tape serves only to hold sealing rope in place during installation. It will disintegrate over time. If collector hood and sealing rope is removed for any reason, new tape and new gasket must be applied.

Double-faced tape applied to

Flat-stitched flange sealing rope

 

Extend rope 1/4"

Bend rope do not

past open ends

cut or stretch

 

Flue collector hood end cap

Flue collector hood modules

Figure 9 Sealing Rope Application on Collector Hood Assembly

10

Part No. 550-141-705

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