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Weil-McLain 4 Series Manual

Weil-McLain 4 Series Manual

Steam boiler
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94
Steam Boiler - Series 4
For use with Gas, Light Oil, and Gas
with Light Oil Fired Burners
Boiler Manual
WARNING
!
Installation and service of the boiler must be performed by a qualified installer or service technician.
Read all instructions, including this manual and all other information shipped with the boiler, before
installation or operation. Perform steps in the order given. Failure to comply could result in severe
personal injury, death or substantial property damage.
Manual Part Number 550-100-157/0523

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Summary of Contents for Weil-McLain 4 Series

  • Page 1 Steam Boiler - Series 4 For use with Gas, Light Oil, and Gas with Light Oil Fired Burners Boiler Manual WARNING Installation and service of the boiler must be performed by a qualified installer or service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installation or operation.

  • Page 2: Table Of Contents

    Table of ConTenTs sTeam series boiler manual Contents Tools . . . . . . . . . . . . . . . . . . . . . . . . 4 Steam Boiler Controls .
  • Page 3 sTeam series boiler manual Table of ConTenTs SECTION 3 - MAINTENANCE SECTION 4 - PARTS Maintenance - General . . . . . . . . . . . . . . 53 Miscellaneous Parts .

  • Page 4: Tools

    Table of ConTenTs sTeam series boiler manual Tools Abbreviations Table 1 Table 2 Common tools needed Common abbreviations Abbreviation Description Tools Needed Purpose AHRI Air-Conditioning, Heating, and 1/16" flat blade screwdriver Wiring onto terminal blocks Refrigeration Institute Phillips head screwdriver Jacket posts and channels ANSI American National Standards Institute...

  • Page 5: Section 1 - Safety

    sTeam series boiler manual safeTy SeCTion 1 Safety Please Read Before Proceeding This section is intended to provide safety information for installers and users WARNING Section Contents Adhere to all following guidelines and instructions in this section. Failure to adhere to Safety Signals these guidelines can result in severe personal Please Read Before Proceeding...

  • Page 6: Boiler Operation

    safeTy sTeam series boiler manual Please Read Before Proceeding, continued Boiler Operation Freeze Protection Fluids • Do not block flow of combustion or ventilation air NEVER use automotive or standard glycol antifreeze to boiler Use antifreeze specifically made for hydronic •...

  • Page 7: Section 2 - Installation

    sTeam series boiler manual insTallaTion SeCTion 2 Installation This section is intended to provide installation IMPORTANT instructions for qualified heating installers. The 94 Series 4 steam boiler met safe lighting and Section Contents other performance criteria when the boiler underwent tests specified in UL 726 &...

  • Page 8: Flooring And Foundation

    insTallaTion sTeam series boiler manual Prepare Boiler Location, continued Flooring and Foundation Figure 1 Boiler foundation, when required The 94 boiler is approved for installation on Always use steel strips as combustible flooring, but must never be installed on shown for proper draw-up and alignment of sections.

  • Page 9: Clearances

    sTeam series boiler manual insTallaTion Clearances IMPORTANT There are minimum clearance requirements for the boiler from combustible surfaces There are Without the recommended minimum clearances for recommended service access clearances See service access, it may not be possible to service the Figure 2 for all clearances boiler without removing it from the space.

  • Page 10: Prepare The Boiler

    Follow all removal instructions. Boiler Model Length Lifting Weight Number (Crane Hook to (lbs .) IMPORTANT Boiler Lifting Lugs) Cables used for lifting are not provided by Weil-McLain. 1494 13700 5' 0" 1594 14500 5' 0" WARNING 1694 15400 5' 0"...

  • Page 11: Removing A Preassembled Block From The Crate

    Check the gas-tight seal of the flue collector hood and clean out plates IMPORTANT a Check inside the section assembly for any light Cables used for lifting are not provided by Weil-McLain. passing through unsealed areas b Mark all unsealed areas and check for the WARNING...

  • Page 12: Boiler Assembly

    insTallaTion sTeam series boiler manual Boiler Assembly Assembling the Block Figure 3 Sealing rope adhesive WARNING Ensure sections are supported. Sections are top- heavy. Unbolted sections may fall if not supported, which can result in severe personal injury or death. NOTICE Machined port surfaces must remain clear of any adhesive properties.
  • Page 13 sTeam series boiler manual insTallaTion Assembling the Block, continued Figure 5 Silicone sealant NOTICE Do not use petroleum based cleaning or sealing compounds in the boiler system; usage can result in severe boiler damage and substantial property damage. Remove any grit from port machined surfaces with a clean rag Place 9"...
  • Page 14 insTallaTion sTeam series boiler manual Boiler Assembly, continued Assembling the Block, continued Figure 6 Sealing ring installation and port alignment Install the intermediate sections: Section Section Metal- Remove and discard 3/8" diameter shipping tie to-metal contact rods Remove grit from port machined surfaces with Silicone clean rag sealant...
  • Page 15 sTeam series boiler manual insTallaTion Table 5 Section arrangement Placement of special intermediate sections (TI and SI) Numbering from REAR to FRONT, beginning with rear section as section number 1 TI = Tankless Intermediate section Steam SI = Supply Intermediate section Boiler Models TI sections with tankless coil openings...

  • Page 16: Boiler Connections For Pressure Testing

    insTallaTion sTeam series boiler manual Boiler Assembly, continued Boiler Connections for Pressure Testing Plug or use blind flanges on remaining tappings. NOTICE Install the boiler connections per the appropriate instructions below according to the boiler model Do not pressure test with any control installed. Damage to control can occur due to overpressure.
  • Page 17 sTeam series boiler manual insTallaTion Figure 7 Model 94 steam boiler control tappings Location Size Function Top front supply Top front supply 10” FLG (2194–2594) 2194 – 2594 2194 – 2594 Pressure test gauge — REMOVE AFTER HYDROSTATIC TEST J1 + J5 Gauge glass Front supply elbow Front supply elbow...

  • Page 18: Connect Steam Boiler Piping

    insTallaTion sTeam series boiler manual Boiler Assembly, continued Connect Steam Boiler Piping piping close to boiler See Figure 7, page 17 for sizing Hartford loop piping arrangement and wet return are Connect cold water fill piping as shown in Figure 8 required for steam boilers Use the Hartford loop for Recommended valves and water meter are also both pumped-return and gravity-return systems...

  • Page 19: Steam Boiler Piping Guidelines

    Consult result in serious damage to system components and a local Weil-McLain distributor or sales office before oxygen corrosion due to excess makeup water. installing alternate piping...
  • Page 20 insTallaTion sTeam series boiler manual Boiler Assembly, continued Steam Boiler Piping Guidelines, continued Figure 11 Models 2194-2594 steam piping – two 10" risers required e r H e r H H e a d H e a d R i s e r R i s e r R i s e r R i s e r...
  • Page 21 Use a control on each boiler with body mark at level indicated in Weil-McLain Boiler Control System (such as a BCP panel) Figure 38, page 30 Provide one of the following at point A:...

  • Page 22: Burner Mounting Plate Installation

    insTallaTion sTeam series boiler manual Boiler Assembly, continued Burner Mounting Plate Installation If using "TI" sections, install tankless or storage heaters and gaskets, or heater plates and The following instructions assume a burner mounting gaskets Use 3/8" cap screws plate supplied with the boiler For H-94 boilers, if a Jacket Installation Guidelines burner mounting plate was not ordered, the plate must be made according to burner requirements...

  • Page 23: Preparing Jacket Panels For Use

    sTeam series boiler manual insTallaTion Preparing Jacket Panels for Use NOTICE Determine which of the knockout openings in the jacket panels will be used from the control The jacket side panels can be placed on either side tapping table in Figure 7, page 17 of the boiler.

  • Page 24: Installing Front And Rear Jacket Panels

    insTallaTion sTeam series boiler manual Boiler Assembly, continued Installing Front and Rear Jacket Panels Table 7 Placement of support brackets — sections are numbered from back to front Install jacket brackets on the tie rod lugs of the front and rear sections as shown in Inset A and Install brackets Install brackets Boiler...
  • Page 25 sTeam series boiler manual insTallaTion Figure 14 Installation of jacket support brackets, support channels, and corners (piping and other components omitted for clarity) r m a n r m a n T i n n e T i n n e B r a c k B r a c k n u t...

  • Page 26: Installing Front Cleanout Doors

    insTallaTion sTeam series boiler manual Boiler Assembly, continued Installing Front Cleanout Doors Figure 15 Front section block assembly components See Figure 15, items K20 (cleanout door assembly), K22 (hinge for cleanout door), and K24 (hinge plate for cleanout door) for door installation Apply a 1/8"...

  • Page 27: Installing The Flue Collar

    sTeam series boiler manual insTallaTion Installing the Flue Collar Figure 16 Rear section block assembly components See Figure 16, item D (flue collar assembly). Thread two 1/2" nuts on round end of 1/2" x 4-1/4" stud Lock nuts together Thread flat end of stud into tapped hole inside flue-way outlet Remove nuts Repeat steps 1-3 for the remaining three studs...

  • Page 28: Tankless Heaters

    insTallaTion sTeam series boiler manual Tankless Heaters Hot Water Precautions Figure 17 Hot water danger DANGER D A N G E R Hot water can scald! Water heated to a temperature suitable for clothes washing, dish washing, and other sanitizing needs will scald and cause injury (Figure 21).

  • Page 29: Steam Boiler Controls

    sTeam series boiler manual insTallaTion Steam Boiler Controls Installing the Controls Figure 19 Steam control siphon and fittings Install all controls as specified in the figures and tables on this page and pages 30-31 WARNING n t r Failure to properly install, pipe, and wire boiler controls can result in severe personal injury, death, or substantial property damage that is not covered by boiler warranty.
  • Page 30 insTallaTion sTeam series boiler manual Steam Boiler Controls, continued Figure 20 Model 94 steam boiler control tappings Location Size Function Top front supply Top front supply 10” FLG (2194–2594) 2194 – 2594 2194 – 2594 J1 + J5 Gauge glass PLUG this tapping —...
  • Page 31 sTeam series boiler manual insTallaTion Figure 21 Water level control locations Primary Casting line Backup Casting line Water height above Water height above Primary Level bottom of Level bottom of water Secondary Control gauge glass Control gauge glass level water control "A"...

  • Page 32: Baffle Assembly And Installation

    insTallaTion sTeam series boiler manual Baffle Assembly and Installation Boiler Baffle System C-channel parts into the proper length for each boiler size See Figure 22 and Table 9 The 94 Series 4 baffle system is a combination of two types of baffles. The first baffle type is for the two 2nd 3rd flue-ways (inner): flue-ways (outer), and the second baffle type is for the Left-hand and right-hand sub-assemblies are...

  • Page 33: Installing The 2Nd Flue-Way Baffles

    sTeam series boiler manual insTallaTion Installing the 2nd Flue-Way Baffles Figure 25 C-channels installed – boilers 1494-1894 Before installation, open either the left-hand or Front view Top view Bottom view right-hand flue-way door to access the 2nd and 3rd (partial) flue-ways on that side.
  • Page 34 insTallaTion sTeam series boiler manual Baffle Assembly and Installation, continued Installing the 2nd Flue-Way Baffles, cont. Figure 26 C-channels installed – boilers 1994-2594 Before installation, open either the left-hand or right- Front view Top view hand flue-way door to access the 2nd and 3rd flue- (partial) ways on that side Boilers 1994 through 2594...

  • Page 35: Assembling The 3Rd Flue-Way Baffles

    sTeam series boiler manual insTallaTion Assembling the 3rd Flue-Way Baffles Figure 27 Baffle plate width holes per boiler size Confirm the quantity of rectangular baffle plate configurations is correct for the boiler size. Refer to Figure 46, page 65 Each boiler size requires a different width of baffle in the 3rd flue-way.
  • Page 36 insTallaTion sTeam series boiler manual Baffle Assembly and Installation, continued Assembling the 3rd Flue-Way Baffles, cont. Figure 29 Spacer bracket installation Complete the baffle assembly. Refer to Figure 29. Slide spacer Slide spacer Screw into the Screw into the a Align the slot of the spacer bracket with the aligned baffle holes aligned baffle holes bracket up until...

  • Page 37: Installing The 3Rd Flue-Way Baffles

    sTeam series boiler manual insTallaTion Installing the 3rd Flue-Way Baffles Figure 30 Clevis pin installation The 3rd flue-way assembled baffles come in Clevis pins combinations of four, five, and seven rectangular flat plates, with small side flanges affixed between four side rails The bottom of each baffle is indicated by the half- circle lifters spot-welded onto the side rails Confirm that the quantity of available assembled...

  • Page 38: Commonwealth Of Massachusetts Installations

    insTallaTion sTeam series boiler manual Commonwealth of Massachusetts Installations Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts, the boiler must be installed by a licensed plumber or gas fitter. Read and comply with the instructions below. REQUIREMENTS: For all sidewall horizontally-vented EXEMPTIONS: The following equipment is exempt from gas-fueled equipment installed in every dwelling, building or...

  • Page 39: Venting And Combustion Air - General

    sTeam series boiler manual insTallaTion Venting and Combustion Air - General Code Compliance Table 10 Corrosive contaminants and sources Venting and combustion air piping installations must Products to avoid provide provisions in accordance with the section, Spray cans containing chloro/fluorocarbons “Air for Combustion and Ventilation,”...

  • Page 40: Venting And Combustion Air Options

    insTallaTion sTeam series boiler manual Venting and Combustion Air Options Existing Category I Vent System WARNING Turn on the clothes dryer and any other appliance Follow all venting and piping instructions. Failure not connected to the common venting system Turn to follow all instructions can cause flue gas on all exhaust fans, except for a summer exhaust spillage and carbon monoxide emissions, which...

  • Page 41: Room Air Openings

    sTeam series boiler manual insTallaTion Room Air Openings Combustion Air Provision Special Considerations The 94 commercial boiler can use inside air if no Tight construction contaminants are present in the boiler space If contaminants are likely to be present, install the The National Fuel Gas Code –...
  • Page 42 insTallaTion sTeam series boiler manual Room Air Openings, continued Figure 33 Minimum combustion air openings Air openings 94 boiler WITH other appliances in 94 boiler WITHOUT other The required air opening sizes below are FREE the same room appliances in the same room AREA, after reduction for louver obstruction See the important below for large spaces 0 to 12"...

  • Page 43: Breeching And Venting

    sTeam series boiler manual insTallaTion Breeching and Venting General Venting Information Figure 34 Metal breeching, models 894-2194 Model 94 boilers operate with positive pressure Adjust damper assembly during burner start-up to achieve 0 1" W C positive pressure at damper sample hole See Figure 43, page 51 WARNING Seal the venting system gas-tight, and connect...

  • Page 44: Gas Venting Requirements - General

    See Table 12 for technical data for an engineered WARNING vent system Weil-McLain recommends contacting your preferred vent supplier to provide design Conventional Category I flue pipe should not be used as it could leak flue gases, carbon...

  • Page 45: Types Of Gas Venting Systems

    sTeam series boiler manual insTallaTion Types of Gas Venting Systems Figure 35 Category III venting, single boiler (typical shown) Category III venting: positive pressure and not likely to condense in the vent . Boiler, breeching and vent operate at positive pressure The entire engineered vent system must be rated for Category III venting Ensure 0 1"...

  • Page 46: Oil Venting Requirements

    insTallaTion sTeam series boiler manual Oil Venting Requirements Using a Chimney Vent Piping Materials WARNING Due to the use of an oil burner for a 94 Series 4 A chimney must be completely lined in steam boiler, vent material certified to UL 641 should accordance with Installation of Oil Burning be used All alternate venting systems are at the Equipment –...

  • Page 47: General Oil Venting Information

    51 for more information with local authority having jurisdiction See Table 12 for technical data for an engineered Engineered Vent System vent system Weil-McLain recommends contacting your preferred vent supplier to provide design WARNING support Conventional flue pipe should not be used...

  • Page 48: Oil Venting System

    insTallaTion sTeam series boiler manual Oil Venting Requirements, continued Oil Venting System Figure 38 Positive pressure venting, single boiler (typical shown) Positive pressure venting: Boiler, breeching and vent operate at positive pressure The entire engineered vent system must be rated for positive pressure venting Ensure 0 1" positive pressure at test opening The minimum vent height is 3 feet above roof or snow line, and in accordance to local codes that have jurisdiction See...

  • Page 49: Install Burner And Fill The System

    sTeam series boiler manual insTallaTion Install Burner and Fill the System Burner Installation Figure 41 Limit chain diagram Unpack the burner Place the gasket around the air tube and against Low Water High Limit the burner mounting flange. If sealing rope Cutoff is used, apply 1/8"...

  • Page 50: Fuel Piping

    insTallaTion sTeam series boiler manual Fuel Piping Gas Piping Figure 42 Gas supply piping Consider these factors when sizing the gas piping: • Diameter and length of the gas supply piping • Number of fittings. Manual main shut off gas valve •...

  • Page 51: Final Adjustments

    sTeam series boiler manual insTallaTion Final Adjustments Adjust the Burner and Damper Assembly Figure 43 Flue collar damper assembly NOTICE Make final burner adjustments using combustion test equipment to assure proper operation. Do not fire boiler without water. Sections will overheat, Test plug damaging the boiler and resulting in substantial property damage.

  • Page 52: Skim Steam Boilers

    insTallaTion sTeam series boiler manual Final Adjustments, continued Skim Steam Boilers Check the Boiler for Gas-Tight Seal WARNING NOTICE Boiler must be sealed gas-tight to prevent Clean all newly installed steam boilers to remove possible flue gas leakage and carbon monoxide oil.

  • Page 53: Section 3 - Maintenance

    sTeam series boiler manual mainTenanCe SeCTion 3 Maintenance This section is intended to provide maintenance concluded, "Crystalline silica inhaled in the form of instructions and timing for the boiler quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1) " Section Contents Use of an N95 respirator is based on the OSHA requirements for cristobalite at the time this...

  • Page 54: Annual Inspection

    mainTenanCe sTeam series boiler manual Annual Inspection General Inspection Information Inspect All Piping for Leaks WARNING WARNING Shut off the fuel supply to the boiler while Eliminate all system or boiler leaks. Piping leaks servicing to avoid a potential explosion, which can result in severe personal injury, death, or can result in server personal injury, death, or substantial property damage.

  • Page 55: Boiler Service And Maintenance

    sTeam series boiler manual mainTenanCe Boiler Service and Maintenance Service and Maintenance Schedules Service Technician Owner Maintenance (use this manual for instructions) (see the User Manual for instructions) General: ‰ Check the boiler area ‰ Check air openings ‰ Investigate reported issues ‰...

  • Page 56: Cleaning Heating Surfaces And Flue-Ways

    mainTenanCe sTeam series boiler manual Boiler Service and Maintenance, continued Cleaning Heating Surfaces and Flue-ways Cleaning the Water Side of the Boiler NOTICE If the water side of the boiler must be cleaned or inspected, open the blowdown valve and drain Do not brush or vacuum the firebox or combustion the boiler chamber area of those boilers using fibrous...

  • Page 57: Cleaning The Gauge Glass

    sTeam series boiler manual mainTenanCe Cleaning the Gauge Glass Troubleshooting — Priming or Foaming Close the lower gauge glass cock and carefully Foaming or priming in a steam boiler can cause open the petcock below the glass to blow water large quantities of water to pass into the steam and sediment out of the gauge glass by steam mains, resulting in violent fluctuations of water...

  • Page 58: Seasonal Boiler Shutdown

    mainTenanCe sTeam series boiler manual Boiler Service and Maintenance, continued Seasonal Boiler Shutdown Long-Term Boiler Shutdown NOTICE When the boiler and system must be drained for long-term shutdown, perform the following Do not drain boiler during periods of shutdown unless procedures exposed to freezing temperatures.

  • Page 59: Section 4 - Parts

    Technologies distributor Specify the boiler model and size when ordering Include the description and part Miscellaneous Parts number of the replacement part Part numbers are Ordering found on www weil-mclain com and the following pages Replacement Parts Dimensions CAUTION Miscellaneous Parts...

  • Page 60: Replacement Parts

    ParTs sTeam series boiler manual Replacement Parts Table 15 Parts and numbers for Figure 44, page 61 Item Description Part Number Front section (casting # 9517) 318-102-508 Back section water & steam w/8” round return flange (casting # 9518) 318-102-518 Back section water only for 10”...
  • Page 61 sTeam series boiler manual ParTs Figure 44 Replacement boiler parts 230059 550-100-157/0523...
  • Page 62 ParTs sTeam series boiler manual Replacement Parts, continued Table 16 Parts and numbers for Figure 45, page 63 Boiler Size with Quantity Needed Mfr . Part Weil-McLain Item Description Manufacturer Number Part Number Gauge glass 5/8" diameter Weil-McLain — 383-600-002 X 10-5/8"...
  • Page 63 sTeam series boiler manual ParTs Figure 45 Gauges and valves 230060 550-100-157/0523...
  • Page 64 ParTs sTeam series boiler manual Replacement Parts, continued Table 17 Parts, numbers, and quantities for Figure 46, page 65 Item Description Part Number Baffle 24" Lg 3rd FW 1494-2194 (left-hand baffle, right-hand baffle, locator bracket, spacer bracket, hardware) 388-137-000 Baffle 30" Lg 3rd FW 1494-2194 (left-hand baffle, right-hand baffle, locator bracket, spacer bracket, hardware) 388-137-001 Baffle 42"...
  • Page 65 sTeam series boiler manual ParTs Figure 46 Baffles Locator bracket Spacer bracket Note: These two brackets and hardware included in kits for items 200-205 Blocker piece Note: This blocker piece and hardware included in kits for items 206 and 207 230147 550-100-157/0523...

  • Page 66: Dimensions

    ParTs sTeam series boiler manual Dimensions Table 18 Dimension information for Figure 47, page 67 Dimensions (inches) Model 1494 119-5/8 7-11/16 — 16-3/8 88-1/2 1594 125-5/8 7-11/16 — 16-3/8 94-1/2 1694 131-5/8 7-11/16 — 16-3/8 100-1/2 1794 119-5/8 7-11/16 — 16-3/8 106-1/2 1894...
  • Page 67 sTeam series boiler manual ParTs Figure 47 Dimensions 16-3/8, O.D. 2194 – 2594 1494 – 2094 Tankless heater Tankless heater 73-3/4 insertion/removal insertion/removal clearance clearance Diameter Bolt circle 19-1/4 Maximum burner opening 24-11/16 1494 – 2094 Steel strips FRONT 2194 – 2594 REAR 2194 –...
  • Page 68 ParTs sTeam series boiler manual This page intentionally left blank 550-100-157/0523...

  • Page 69: Section 5 - Service Information

    sTeam series boiler manual serviCe informaTion SeCTion 5 Service Information Section Contents Ratings Installation and Service Certificate Maintenance Log Notes Ratings Table 19 Ratings and engineering data Boiler Flue Boiler Burner Shipping Gas Ratings Oil Ratings Outlet Water Capacity Weight Dia .

  • Page 70: Maintenance Log

    serviCe informaTion sTeam series boiler manual Maintenance Log High fire / Date Stack Temp Action Technician Low Fire 550-100-157/0523...

  • Page 71: Installation And Service Certificate

    sTeam series boiler manual serviCe informaTion Installation and Service Certificate Boiler Model: Series: Consumer Protection Number (CP): Date Installed: BTU Input: ‰ Installation instructions have been followed ‰ Checkout sequence has been performed ‰ Above information is certified to be correct. ‰...
  • Page 72 WM Technologies, LLC 500 Blaine Street Michigan City, IN 46360-2388 Telephone: (800) 654-2109 weil-mclain.com Manual Part Number 550-100-157/0523...

This manual is also suitable for:

149415941694179418941994

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