Weil-McLain 78 User Manual

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

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

Boiler Manual

• Installation

• Start-Up

• Maintenance

• 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.

Part No. 550-141-705

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

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.

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.

Read all instructions before installing. Failure 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 propety damage.

• Installation • Start-Up • Maintenance • Parts

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.

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.

Part No. 550-141-705

Figure 1 Combustion and Ventilation Air

Openings Boiler Room Below Grade

Figure 2 Combustion and Ventilation Air

Openings Boiler Room Partially or Completely

Above Grade

GRADE

Grating – Min. 12" above avg. snowline

Louver – Min. 12" above avg. snowline

Note: Duct size equal to total louver area

Areaway

Louver

Boiler room floor

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

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

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

Part No. 550-141-705

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

• Installation • Start-Up • Maintenance • Parts

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.

Part No. 550-141-705

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

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

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.

Part No. 550-141-705

Cut off rope

even with

edges

Sealing rope

Cut off rope even with edge

7 1/2" Sealing ring

Sealing rope

Cut out observation port opening

Back refractory (apply waterglass to entire back side)

3 1/2” Sealing ring

Figure 4

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.

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.

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

Assemble Block

Part No. 550-141-705

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.

If you would like to pressure-test block

assembly now, proceed to page 12.

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

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

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.

Part No. 550-141-705

Flat-stitched sealing rope

Bend rope do not cut or stretch

Flue collector hood modules

Extend rope 1/4" past open ends

Double-faced tape applied to flange

Flue collector hood end cap

Figure 9 Sealing Rope Application on Collector Hood Assembly

+ 22 hidden pages