Weil-McLain 94 Series Manual
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Weil-McLain 94 Series Manual

Water & steam boilers for use with gas, light oil, & gas/light oil-fired burners
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Boiler Manual
This manual must only be used by a qualifi ed
heating installer/service technician. Read
all instructions before installing. Follow
all instructions in proper order. Failure
to comply could result in severe personal
injury, death or substantial property damage.
94
Series 3
Water & steam boilers
for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners
• Installation
• Startup
Consider piping and installation when determining
INSTALLER
boiler location.
Any claims for damage or shortage in shipment must be
fi led immediately against the transportation company
by the consignee.
This manual is for use only by your qualifi ed heating
USER . . . .
installer/service technician. Boiler and burner must be
installed by a qualifi ed service technician. We recom-
mend regular service by a qualifi ed service technician,
at least annually.
• Maintenance
• Parts
For additional
information, refer to . .
Burner specifi cation
and data sheets
(for burners pre-tested with
model 94 boilers)
Part No. 550-110-275/1018

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Summary of Contents for Weil-McLain 94 Series

  • Page 1 Series 3 Water & steam boilers for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners Boiler Manual • Installation • Maintenance • Parts • Startup For additional information, refer to . . Burner specifi cation and data sheets (for burners pre-tested with model 94 boilers) This manual must only be used by a qualifi...
  • Page 2 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Read before proceeding Read before proceeding: Hazard Definitions Read all instructions before installing. Fail- The terms defined below are used throughout this manual...

  • Page 3: Table Of Contents

    Boiler manual: • Installation • Start-Up • Maintenance • Parts Contents Before installing boiler ....... . . 4 Set boiler in place .

  • Page 4: Before Installing Boiler

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Before installing boiler Installation must comply with — Figure 1 Boiler foundation, when required — always use steel strips as shown for 1. State, provincial and local plumbing, heating and electrical codes.
  • Page 5 Boiler manual: • Installation • Start-Up • Maintenance • Parts Before installing boiler (continued) Combustion and ventilation air openings Figure 3 Combustion and ventilation air openings — Boiler room below grade 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.
  • Page 6 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Before installing boiler (continued) freely communicate with the outdoors, as follows: Mechanical Combustion Air Supply • Where directly communicating with the outdoors or...

  • Page 7: Set Boiler In Place

    Loose bolts or nuts. d. Correct all conditions and repeat step b. If unsealed areas still 2294 20600 7' 6" exist, contact your Weil-McLain distributor or sales office before continuing installation. 2394 21500 7' 6" 9. Check gas-tight seal of flue collector hood and cleanout plates.

  • Page 8: Assembling The Block

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Assembling the block Sections are top heavy. Unbolted sections may fall if not Figure 6 Sealing rope installation supported, resulting in severe personal injury or death.
  • Page 9 Figure 8 Sealing ring installation and port alignment, typical 3. Position intermediate section so aligning lugs fit into Weil-McLain cast iron section nipple port 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.
  • Page 10 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Assembling the block (continued) e. If, for any reason, the gap around machined port open- 6. Check each section for proper sealing rope position before proceeding to next section.

  • Page 11: Perform Hydrostatic Pressure Test

    Boiler manual: • Installation • Start-Up • Maintenance • Parts Perform hydrostatic pressure test Install boiler connections 2. Secure 10" supply outlets and gaskets on top of "SI" sections. • Supply outlet installed close to boiler front should have 1¼" tapping facing front. 894 –...

  • Page 12: Control Tapping Locations - Water Boilers

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Control tapping locations — water boilers Figure 10 Model 94 water boiler control tappings Item # Function Size (Inches NPT) PRESSURE TEST GAUGE — REMOVE AFTER ½...

  • Page 13: Control Tapping Locations - Steam Boilers

    Boiler manual: • Installation • Start-Up • Maintenance • Parts Control tapping locations — steam boilers Figure 11 Model 94 steam boiler control tappings Item # Function Size (Inches NPT) PRESSURE TEST GAUGE — REMOVE AFTER ½ HYDROSTATIC TEST ½ J1 + J5 Gauge glass ½...

  • Page 14: Connect Water Boiler Piping

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Connect water boiler piping General water piping information Figure 12 Water boiler piping, typical 1. System water supply and return piping should be installed and piping connections attached to boiler before erecting jacket or installing controls.
  • Page 15 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: Connect Steam Boiler Piping

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Connect steam boiler piping General steam piping information: Figure 18 Cold water fill piping 1. Hartford loop piping arrangement and wet return are required for steam boilers.
  • Page 17 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 Minimum height of header above water line must...
  • Page 18 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Connect steam boiler piping (continued) Figure 23 Model 2194 through 2594 steam (2 10-inch risers required) Model Riser A Riser B Header H...
  • Page 19 Use • For pumped-return systems, install boiler water level a Weil-McLain Boiler Control System (such as a BCP control on each boiler with body mark at level indicated panel) to open each steam valve automatically before in Figure 38, page 30.

  • Page 20: Complete Block Assembly & Install Jacket

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Complete block assembly & install jacket Burner mounting plate Before installing jacket 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.
  • Page 21 Boiler manual: • Installation • Start-Up • Maintenance • Parts Complete block assembly & install jacket (continued) Figure 25 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"...
  • Page 22 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Complete block assembly & install jacket (continued) DO NOT loosen the tie rod nuts when installing c. When completed, there will be four brackets on each section listed in Figure 26.
  • Page 23 Boiler manual: • Installation • Start-Up • Maintenance • Parts Complete block assembly & install jacket (continued) Figure 27 Installing jacket support brackets, support channels and corners (piping and other components omitted for clarity) Part No. 550-110-275/1018...
  • Page 24 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Complete block assembly & install jacket (continued) Install front cleanout doors K41(refractory shield for back access door). 2. Insert access door shield into opening in back section.

  • Page 25: Pipe Tankless Heaters

    7. In hard water areas, soften cold domestic water supply to heaters to prevent lime build-up. Consumer Product Safety Commission and some Figure 30 Tankless heater ratings (Weil-McLain ratings) states recommend domestic hot water tempera- Heater Intermittent draw Continuous draw Inlet and ture of 130°F or less.

  • Page 26: Install Water Boiler Controls

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Install water boiler controls Install controls: Figure 32 Model 94 water boiler control tappings 1. Install furnished controls per Figure 32 and Fig-...
  • Page 27 Boiler manual: • Installation • Start-Up • Maintenance • Parts 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: Install Steam Boiler Controls

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Install steam boiler controls Install controls: Figure 34 Model 94 steam boiler control tappings 1. Install controls where shown in Figure 34 and...
  • Page 29 Boiler manual: • Installation • Start-Up • Maintenance • Parts Install steam boiler controls (continued) Figure 35 Figure 36 Model 94 steam boiler control tappings Steam control siphon and fi ttings Manifold component sizing (Check local codes for sizing and cleanout requirements) Item Description Size (inches)
  • Page 30 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Install steam boiler controls (continued) Figure 37 Figure 38 Float-type water level control locations Water level control locations (see Figure 37) Primary Casting line...

  • Page 31: Connect Breeching And Venting Systems

    Boiler manual: • Installation • Start-Up • Maintenance • Parts Connect breeching and venting systems Seal the venting system gas-tight and connect the breech- Figure 39 Minimum breeching diameter 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.
  • Page 32 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Connect breeching and venting systems Figure 40 Figure 41 Conventional chimney — balanced draft with Stub vent — forced draft — single boiler barometric draft control when required —...
  • Page 33 Boiler manual: • Installation • Start-Up • Maintenance • Parts Install burner & wiring and fill system To install burner For unusually hard water areas or low pH conditions (less than 7.0) consult local water treatment company. 1. Unpack burner. Provide a water softener for make-up water if hardness exceeds 7 grains.

  • Page 34: Install Fuel Piping

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Install fuel piping Gas piping Figure 43 Gas supply piping 1. In sizing the gas piping, the following factors should be considered: a. Diameter and length of the gas supply piping.

  • Page 35: Make Final Adjustments

    Adjust the burner if possible to redirect the fl ame. If this does not work, contact your boiler supplier or Weil-McLain to obtain an optional combustion chamber kit (see page 44 for contents). 10. Re-insert plug at boiler skim tapping.

  • Page 36: Handling Ceramic Fiber And Fiberglass Materials

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 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.

  • Page 37: Maintenance And Troubleshooting

    Boiler manual: • Installation • Start-Up • Maintenance • Parts Maintenance and troubleshooting Figure 45 Service and maintenance schedules Owner maintenance Service technician (see following pages for instructions) Inspection — all boilers • Inspect boiler area — must be • Discuss any reported problems with owner/operator.
  • Page 38 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Maintenance and troubleshooting (continued) Read before proceeding Water chemistry and make-up The boiler must be inspected, Do not use petroleum-based clean- cleaned as necessary, started up and ing or sealing compounds in boiler adjusted by a qualified boiler service...
  • Page 39 Boiler manual: • Installation • Start-Up • Maintenance • Parts Maintenance and troubleshooting (continued) Cleaning boiler heating surfaces and purities. It may be necessary to drain several gallons of water until all traces of sediment are gone. Refill the boiler to the flueways proper water level or pressure.
  • Page 40 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Maintenance and troubleshooting (continued) If gauge glass breaks, close off both gauge cocks Troubleshooting — steam boiler priming and loosen the glass retaining nuts to remove gauge or foaming glass.

  • Page 41: Ratings

    "(number or for unusual piping and pick-up loads. required) TIP". Consult local Weil-McLain distributor/agent or sales office. Burner input based on maximum of 2,000 feet altitude. For Water boilers tested for 80 PSIG, ASME water working pressure.

  • Page 42: Dimensions

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Dimensions Dimensions (inches) Model (steam only) (steam only) Water Steam Water Steam ⁄ ⁄ ⁄ — — — ⁄ ⁄ ⁄ ⁄ —...
  • Page 43 Boiler manual: • Installation • Start-Up • Maintenance • Parts Dimensions (continued) Figure 46 Dimensions (INCHES) (see lettered dimensions on opposite page) Part No. 550-110-275/1018...

  • Page 44: Parts

    Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Parts Item Description Part No. Item Description Part No. Front section (casting # 9517) 318-102-508 Wing nut assembly — with 3/8 x 1 ¼’ stud (threads into...
  • Page 45 Boiler manual: • Installation • Start-Up • Maintenance • Parts Parts (continued) Figure 47 Block assembly parts Part No. 550-110-275/1018...
  • Page 46 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Parts (continued) Figure 48 WATER boiler trim and control components Item Description Manufacturer Mfr's Weil-McLain Boiler size part part 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25...
  • Page 47 Figure 49 STEAM boiler trim and control components Item Description Manufacturer Mfr's part Weil-McLain Boiler size number part number (note = alternate components) 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Gage glass ⁄...
  • Page 48 Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Part No. 550-110-275/1018...

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