Weil-McLain 78 Series Installation manual

v
v
Installation Start-up Boiler Parts
PartNo.
550-
l4l-705/0493DCP
v
Boilerfor Gas,
LightOilandGas/Light
Oil FiredBurners

Read
This Page
First
U
Hazard Definitions
The following defined terms are used throughout this manual to bring attention to the presenceof hazards
of various risk levels,or to important information concerning the life of the product.
Indicates presence of hazard which will cause severe personal injury, death
or substantial property damage if ignored.
Indicates presence of hazard which can cause severe personal injury. death
or substantial property damage il'ignored'
Indicates presence of hazard which will or can cause minor personal injury
or property damage if ignored.
Indicates special instructions on installation, operation, or maintenance
which are important but not related to personal injury hazards'
When Calling
or Writing aboutthe Boiler
please have model and series fiom boiler rating label ancl CP number(s) fronr boilcr jackct or controls.
Do not use petroleum-based cleaning
Severe
damageto system components can or sealingcompounds in boiler system.
result, causing substantial property damage.
Read all instructions before installing.
Failure t.o
follow all instructions in proper order can cause
severe personal injury, death or substantial property clanrage'

Tableof Contents
vSection A: Before Installing Boiler.... ..'.4 - 5
Section B: Set Packaged Boiler or Block Assembly in Place 6
Section
C:Assemble
Block .......7
- 12
Section D: Perform Hydrostatic PressureTest .......'.13
Section E: Connect Water Piping ....
'.14 - 15
Section F: Connect Steam Piping ......16 - 19
Section
G: Install Jacket .........2O
Section
H: Pipe
Tankless Heaters .............2O
Section
I: Install Water Boiler Controls ...........21
Section J: Install Steam Boiler Controls ....22 - 23
Section K: Connect Breechinfl and Venting Systems .......'24
Section
L: Install
Burner .'........25
Sectiot't
M: Wiring and F-uel
Piping ....---....25
Section
N: Make Final
Adiustnlents
... ..'....26
- 27
Section
O: Data and Dimensions .'...28 - 29
Section
P:Parts .....3O
- 3l
Ratings ..Back Cover
b

Section
A: BeforeInstalling
Boiler
Installations must comPlY with:
o State. pro','incial and local plumbing, heating and
electrical codes.
o Regulations of senring utilities.
o National codes where applicable.
Before selecting boiler location:
o Check for nearby connections to:
fuel sr-rpply
electrical power
system water or steam PiPing
- r,'entinAsystems - see page 24.
combustion and ventilation air supply - see "Providc
combustion and ventilation air supply openings"
below.
o Check area around boiler for and remove any combus-
tible materials, gasoline and other flammable vapors
ancl liouids. Failure to keep boilcr area clear and
free of combustible materials, Aaso-
line and other flammable liquids and
vapors can rcsult in severc personal
injury, death and substantial proper-
ty damagc.
Providecombustion and ventilation air openings:
Do not install arn
exhaust lan in boiler
room. Adequatc combustion and ventila-
tion air must be provided to assure propcr
combustion and prevent possibility of flue
gas lezrkageand carbon monoxide emis-
sions, 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:
o Provide two penniar-rentopenings in boiler room - one
within 12 inches of ceiling. one ','v'ithinl2 inches of
floor. Minimum dimension of each opening - 3 inches.
- When all air is taken from rvithin building, each
opening should be at least one square inch/
1'ooo Btuh boiler input and freell' connect with
areas having adequate infiitration from outside.
- When all air is taken from outdoors. each opening
should connect directly or by ducts with outdoors
or crawl or attic spaces that lreely connect with
outdoors ancl sized as listed below:
through outside wall or vertical ducts - at least
one square inch/4,000 Btuh boiler input.
- through horizontal ducts - a least one square
inch/2,000 Btuh boiler inPut.
- where ducts are used, they should be same
cross-sectional area as lree area of openings
they are connect.ed to.
- Compcnsate lbr louver, grille or screcn block-
agewhcn calculating liee air openings. Refer to
thcir mzrnufacturer's instntctions lbr size
. If
ttnkrtowlr, ttse:
- wood louvcrs - 2o-25oh free air.
- metal louvers or grilles - 60-750/o
lree air.
- screens - not less than l/4 inch mesh.
l,ock louvers in open position, or interlockwith
equipment to prove open belbre boiler opera-
tion.
LOUVER
MIN,I2"
ABOVEAVG.
SNOWLINE
NOTE:
DUCT
SIZE
EQUAT
TO
TOTAL
LOUVER
AREA
BOILER
ROOI'1
FTOOR
Combustion and Ventilation Air Openings
Boiler Room Partially or Completely Above Grade
Figure 2
o
GRATING
_
MIN,I2'ABOVE
AVG,
SNOWLINE
SIZEOF
AREAWAY
ANDGRATING
TO
BEEQUAL
TOOR
GREATER
THAN
TOTALTOUVER
AREA.
AREAWAY
Combustion and Ventilation Air Openings
Boiler Room Below Grade
Figure I
4
t/

Section
A: Before lnstalling
Boiler coNT'D
UProvide clearancesfor servicing around boiler:
o Back, for breeching - 30 inches
o lrft side, for cleaning and tankless heater removal
- 34 inches
o Allow sufficient space
on remaining sides
for cleaning.
servicing
andburner installation. See
bumer lilerattlre
for length.
o Clearance
fronr
ventpipeto conlbuslible
rnaterials:
- singlewall
ventpipc - l8 inches
- clouble.'vall
vent pipe - rel'erto vent pipe t-llatlul-rctltr-
cr's
re('ontlllendatiot'ts
lbrventpipe
cle:rrances
Lay a foundation, if needed:
Floor constmction and condition must be suitable for
weight ofboiler when filled with water' See
back coverpage
for boiler/water weight.
A level
concrete
or brick foundation is requiredwhen:
o Floor couid possiblybecome
flooded;
o Non-level
conclitions
exist.
*
2"
MIN.
Boiler Foundation
Figure 3
BOILER
FOUNDATION
LENGTH
TABLE
BOILER
MODEL "1"
lNCHES BOILER
MODEL "1"
INCHES
378 23 878 58
478 30 9't8 65
578 37 |078 f2
578 44 It78 79
178 5l t278 85
v

SectionB:Set Packaged
Boiler or BlockAssemblyin Place
For packaged boiler:
1. Removetopjacket panel.Setasideuntil afterboiler
is piped.
Remove lag screws (2 in front, 2 in rear) from shipping
rails.
Remove boilerfrom skid. Cables are already attached to
block assembly. See Lifting Weight Chart.
. Using crane - hook middle of each cable to eye of
crane.
o Using hoist - hook middle of each cable to hoist.
Raise boiler olf skid. Use pipe rollers unc'ler skicl
angles to roll boiler.
Place boiler in final oosition. Center boiler on founda
tion. if used.
5. kvel boiler. Shirn under skid angles, il.necessary
6. Cut off czrbles. Cables are not intendecl for long-term
usage. Cables may corrode inside boil
er. weakening their lifting strength.
Failure to remove cables can result in
severe personal injury, death or
substantial properff damage.
7. Proceed to "Section D: Perforrn Hvdrostatic Pressure
Test," page 13.
For block assembly:
l. Remove lag screws (2 in fiont, 2 in rear) Irom shipping
r:rils.
2. Remove boiler liom skicl. Cables are already atl.ached to
block zrssembly. See Lifting Weight Chart.
o Using crane attach free end ofcables to eye of
orane.
o Using hoist - attach free end of cables to hoist.
Raise boiler off skid. Use pipc rollers under steel
skid angles to roll boiler.
3. Place boiler in final position. Center boiler on founda-
tion. if used.
4. Level boiler. Shim under skid angles. il.necessary.
5. Cut off cables. Cables :rre not intended for lon$-term
usage. Cables nrat'c-orrode inside boil-
cr. .,veakeninq their lifting strength.
Failure 1o
renlove t'erblescan result in
severe personal injtln'. de:rth or sub
stanl
iirl
l)rol)env
drttttate.
Inspecl block assembly lbr clisjointcd scctions. Check
gas-t.ight
seal of llue collector hood. llue collar and
cleanout plates. Gas t.ight seal nrttst l;e nt:rintained trr
prevent possiblc lluc g:rs leakage and
carbon monoxicle enrissirtns, resul-
ting in severepersor-ralin-jury or death.
a. Open damper in flue collar.
b. Check insidc section assembly for any light passing
through unsealecl areas.
c. Mark:rll unsealcd areas.
d. At unsr::rleclarc:rs, check lor darnaged gaskets,
sealing rope not in place, loosc bolts or nuts. or
missin{ holclclorur t'lips. Correct all conditions ancl
rcl)(':lt step l). ll trrtst'irlt'rl
:ireas still t:xist. contact
vour \Vcil-Mt'l;rirt clistrilttttor or s:rlesofTit't:
belirre
continuing installatiol-t.
I)roct:t'cl
to "SecrtionD: I)erlirnn Hvclrostatic I)ressure
Test," pngc 13.
0
2.
tl.
T
LIFTING
WEIGHTCHART
BOILER
MODEL
PACKAGED
BOILER
LBS.
ASSEMBLED
BLOCK
LBS. BOILER
MODEL
PACKAGED
BOILER
LBS.
ASSEMBLED
BLOCK
LBS.
378 |355 It50 878 26s0 2325
418 r6r5 |
385 978 29t0 2560
578 |875 |620 I078 3
r65 2795
678 2t30 |
855 It78 t425 3030
778 2390 2090 1278 3680 3265
6

Section
C:Assemble
Block
Sections are top heary. Unbolted sections
iniury or death. may fall if not supported, resulting in severepersonal
Install back refractory blanket:
l. Lay back section on floor with ports lace up.
2 Apply water glass as an adhesive to blerr.rket.
3. Press blanket against back target wall :rs shotrr in
Fi{ure 4.
1. Using knife. cut hole through blanket to exposc obser
vation poft opening.
Prepare back section:
l. Apply 1/S" continuous bead o1'sealingrope adhesive in
scaling rope grooves. See Figure 4. Do not get any
adhesive on machined port surlaces.
SEALING
Place
I/2" sealingrope
in groove.
Around curves,
grasp
a1l" intenals and push together.
Do not stretch.
E@ :"il$ffi
"::1fi:"r,:?:'.9"1l,T3:
sibility of flue gas leakage and carbon
rnonoxide emissions, causing severe
personal injury or death.
Remove anv grit liorn pofl mzrchined surlaces with
clean rag.
Itr@ 3."J:iJ;
""
#;:':
:]
#fi:1,
:':ili
:
n
tem. Severe darnage Losystem compo-
nents can result, causing substzrnlial
propcrly damage.
Place 7- I /2" and 3-l /2" scaling rings in appropriate
port openings. See Figure 4. If sealing ring slips out ol
groove, stretch ring gently for scverarlseconds, then
reposition in groove.
<-- 7: SEAL1NCRING
SEALING
ROPE
3.
ROPE
4.
BACKREFRACTORY
1APPLY
WATERGTASS
TOENTIRE
BACK
srDE)
cur oFF ,,,,->
ROPEEVEN
/
WITI-1
EDGE
CUTOFF
ROPEEVEN
WITH
EDGE
I
\
!Figure 4

SectionC:Assemble
Block coNT'D
5. Apply continuous bead of siliconesealant no larger
than l/16' around entire outside edge
ofouter
machined surface of port. Referto Figure 5. Do not
apply silicone sealant on, next to or under sealing
ring. Silicone sealant applied as specified
above prevents unburned oil vapors
liom coming in contact with sealing
ring. Vapor contact can damage rings.
resulting in severe dam:r.geto boiler
and substantial propefly clamage.
."'^'=,,
-".
SILICONESEALANT
APPLIEDPERSTEP#5
7
Figure 5
Position section upright on lbundation (if used) and
screw 3" pipe at least 22" long into 3" return tapping
Place a block under pipe to hold section upright.
Prepare intermediate section:
E@ ;'#Hi,?T#3S"ffi
"Y
*:11if;T:1""
"
severe
personalinjury or death.
L Removeand discard 3/8" diameter shipping tie rocls.
2. Removegrit lrom porl machined surfaccs with clean
rag.
E@ 3.'J:ffi
""3ffi:':H:ifi"i,:i"$j*
tem.Severedamage
tosystemcompo-
nents can result, causing substantial
propeny damage.
3. Positionintermediate sectionso aligning lugs fit into
socketsof nexl section.Refer to Figure6.
I
Draw sections together until metal-to-metal contact is
made around machined port openings (seeFigure 6):
a. Oil threacls on 4 drarv rods. Install washer and nut
on end to bc tightencd. Use nut only on other end.
b. Unilbrrnlv clra.,vscctions together. starting atwash-
erlnut end.
c
('.
Draw rods shoulcl bc torqtrccl to a range of 9Oto lOO
ft.-lbs. Do not back ofTclr:ru' rocls.
Metal-to-nrctal t'ontact u'ill bc acl-rievecl
around
porl openings. See Fier-rre 6. Il'Qapdoes exisl, it
should be no gre:rtcr th:rrr .032 . Check wit.h feeler
gauge.
If for any re:lson. g:tp arottnd n'r:rchined porl
opening exceecls .032". r'l-recklbr ropc extencling
liom rope groo\rcs. clirt on por.1
openings or sockets,
or misalignecl lrrgs. Il'c'on'ections zrrc
ntade :rnd g:rp
still exists,conl:r('tr'ourWeil Mcl,ain clistributor or
sillers
olfice belbre continuino installzrtion.
Repeat stcps I
All.er erectin{ flrst intermediate sec-
tion. chcck bottr sections lbr plumb.
Failure to piumb sections can cause
rnisaligned piping ancl brecching,
resrrlting in rninor property damage.
Il lionr "l)reparc l;:lck section."
Figure 6
Instafl bottom refractory blanket on combustion
chamber floor inside section block:
l. Unroll blanket only to depth of back section and first
intermediate section.
2. Spread water glass on bottom side of blanket.
3. Press blanket into center bottom of sections.
4. Unroll and install blanket per steps 2 and 3 as e:rc'h
intermediate and front section are installed.
5. At front section, cut olf blanket 2-1/2' front brtnrer
opening. Discard unused blanket.
I
I
)
/l
,L
,ffi,l
",;4.i4
i:
SEALNG
--l R1NG

SectionC:AssembleBlock coNT'D
Prepare remaining sections:
1. Follow "Prepare interrnediate section" for remaining
intermediate and front sections:
a. Removeany grit from threads inside tapped holes
with ('lean rag. Do not use petroleum-based cle:rn-
ingor sealing compounds in boiler
system. Severe damage to system
components can result, causing
substantial property damage.
l). Install -ll ffankless Intermecliate) and SI (Supply
Intcrmcdiate) sections (when used) in order shown
in "Section Arrangement Table".
(llrcck t'irc'hsec'tionlbr proper sealing rope position
bt'lorc proceecling to next section.
Failure to position sealing rope:
properlv can ('ausc boiler to not
st-al
qas tieht. Clirslialrt scal
pr('\'('nts possilrk' l)rrc
qlrs
lcakaec
;ttlrI
r
,rt
lroI)
It)oIl{)\i(lI
r'ttti\\i(,tl\.
rcsultitrqtn st'r't'rt'pt'rsorrirl
injrrn'
or rlcath.
cl. Mal<r'srrrc bottonr rclr-acton-blankct has br.r'n
irrslalk'rl
I)er
instnrctions on p:rgc8.
lnstall burner mounting plate on front section:
L Install four | / 2" x 1-3/ 4" studs to secure burner mount-
ing plate to section:
a. Thread and lock together trvo nuts on rounded
end of stud. Thread llat end of stud into one of
four holes located around opening.
b. Remove nuts.
c. Repeat steps a and b lbr remaining studs.
2. Install burner mounting plate:
a. Apply l/8' continuous bead of sealing rope adhe-
sive in groove around opening in section.
b. Position l/2" sealing rope in groove. Overlap ends
at least one inch.
c. Install burner mounting plate. Use I /2" washers
and nuts.
Install observation port assemblies on front and back
sections:
l. Instirll lj'orrtolrscn'ation
port assernbly:
l. r\pph' 1/8 t'ontinrrous be:rd ol-sc:rlir.rg
ropc adhe-
sivt' in groo\'(' orr obst'r.r'ntion
port.
lr. ['osiliorr l]/Fi st'irlirrrl ropc irr lroot's. Overlap ends
at l('ils1
ortt'itttlr.
('. Scclrn'asst'rrrblvto se('tioli.Ust'5/l6 18x 3/4"
slotte(l l'tt-itclscreu's.
2. Repeat abovc stcps lirr back obscn':rtiort porl lrssernbly.
lf using Tl sections:
Install lankless hezrterszrnd
gasketsor heaterco'"'er
plates
ancl
gaskets.
Use3/8" x3/4" studsand
nu1s.
Installcleanout plates(seeFigure 7):
Cleanout plates rnust bc installe<l gas-
tight to prcvcnt possibility o1'tltre g:rs
leakage and carbon monclxide enrissions,
resulting in severe
personal injury or death.
l. Position two | /4" x 1 3/4" c:rrriage bolts in cleanout
opening. Secure with washc'rs and nuts.
Place blanket lnsr.rlation piece against cleanotrt plate.
Mounl t:le:rnotrt plate over opening. Secure with nuts
2
Janc'l
washers.
1. Ilcpcat stcps I lhrough3 lbrremainingcleanoutplates
Cleanout Plate
Figure 7
\\r=\\rnter. S=Stearr: F=Front. Tl=Tankless
I=lntenlecli:rte. SI=Supplv Intermediate for
B=Back. "1" sections c:rn be substituted for
Interrnediate,
steam boilers,
'"TI" sections.
l
lu'
6ir
i"-
LI
l
rNsuLArroN
x'
CLEANOUT ]:.]
PLATE --_-_ >\1
".ilii
.
".
!il
"'"
lj[-
If you would like to pressllre-test block assembly now,
proceed to page 13.
9
SECTION
ARRANGEMENTTABLE
BOILER
MODEL
MAXIMUM
NO. OF
HEATERS
SECTION ARRANGEMENT
(all heaters must be on
left sideof boiler)
378W&S IF-TI
-B
478 \^/&S IF-Tt - t-B
578W&S 2F-Tt-t-Tt-B
678W&S 2F-Tt-t-Tt-t-B
778\v&S 2F-Tt-l-Tl-t-r-B
878W&S 3F-Tt-t-Tt-t-t-Tt-B
978\^/&S 3
t078w 3
t078s 3
il78 \^/ 4F-Tt -
t
-Tt -
I
-
t- |
-Tt -
|
-Tt -
B
il78 S 4
r278W 4
r278S 4F
-Tt -
I
-Tt -
|
-St-
|
-
t
-Tt -l -Tt -
B

Section
C:Assemble
Block coNT'D
Install
flue collar assembly:
Make sure gasket is intact, not tom or
otherwise damaged. These conditions can
cause possible flue gas leakage and carbon
monoxide emissions. resulting in severe
personal injury or death.
Place gasket on flue collar flanged surface:
:r. Wipe all flanged surfaces with clean rag.
b. Apply rope adhesive lo enough places on top. sides
and bottom of flange to hold gaskct in place.
c. Carelully lay gasket on flue collar flange. making
strre to line up bolt holes on gasket ancl flangc.
2. Mount collar on back section:
a. Remove any grit lrom threads inside tapped holes
wilh clean raq.
Install one 5/16" x l" flanged bolt hallkay into
bottonr hole in section
Rest llue collar on lizrnged bolt, making sure to
not damage gaskct.
Install 5/I6" x l" ll:rnQecl
bolts in lo"vertwo side
holes.
Tightcn all 3 bolts.
d.
\i
FLUECOLLAR
GASKEI
/[
n
a-..
@
}\
I
g./
e,,
g
, FLUECOLtECTOR
IOOD MODULE
* ra' \,"
Flue Collar and Flue Collector Hood Assemblies
Figure 8
FLUECOttECTOR
HOODGASKET
HoLDDowN Zll
cL'P -_-_--lvo
FLUECOLLECTOR
HOOD
ENDCAP
FLAT,STITCHED
SEATING
ROPE
t
FLUECOLTAR
t0

Section
C:Assemble
Block coNT'D
Prepare flue collector hood assembly:
Make sure gaskets are intact, not torn or
otherwise damaged. These conditions can
cause possible flue gas leakage and car-
bon monoxide emissions. resulting in
severe personal injury or death.
l. Stand one collector hood module on end.
2. Wipe all flanged surlaces with clean rag'
3. Lay gasket on flange. Refer to Figure B.
4. Place end cap on gasket, aligning flanged surfaces.
Secure with six 5/ 16" x 5/8" ilanged bolts and flanged
nuts. Tighten to 30 - 35 in.-lbs.
5. For 878 - ).278:
a. Stand remaining hood modulc on end.
b. Wipe all llanged surfaces with clean rag.
c. tay gasket on flange.
d. Carefully place open end ol'Iirst rnodule on top of
gasket, aligning flangecl surfhces.
c. Secure with six 5/ 16" x 5/8" Ilanged bolts :rncl
Ilanqed nuts.
FLAT-STITCHED
SEALING
ROPE
BENDROPE
DONOT
6. Attach flat-stitched sealing rope to hood assembly. See
Figure 9:
a. l,ay hood on floor rvith flanged side up.
b. Wipe flanged surl-ace rvith clean rag to remove dirt
and oil.
c. Apply double faced tape to llangecl surface'
d. Apply rope to tapc' beqinning on one side of open
end of hood, leaving | / 4" extending past edge.
Around corrlers, bend rope. do not cut. Do not
stretch roPe. Do not pre-cut rope. Gas-tight
seal must be maintained to Pre
vent possible flue gas leakage and
carbon monoxide emissions.
resulting in severe personal
injury or death.
Continue around cntire flange. At other open end,
lc:rve 1/r1" ropc extending past eclge
of flange. Cut
oll exccss ropc. Double-{aced tape selves onlY to
hold sealir-rg
rope in place during
irrsterllation.
Itll.ill disintcgrate over
tinrc. Il'c'ollector
hoocland sealing
ropt- is rentovt'cl for ernv
reason,
new ne\\/ tapc :ttrcl n('w gaskct
rrrrrst
be appliccl.
DOUBLE-FACED
TAPE
APPLIEDTO FLANGE
EXTEND
ROPE
I/4'PASTOPEN
ENDS
FLUECOLLECTOR
HOOD
MODULES
CUTORSTRETCH
FLUECOttECTOR
HOODENDCAP
Sealing
Rope Application on Collector Hood Assembly
Figure 9tl

Section
C:Assemble
Block coNT'D
lnstall flue collector hood assembly:
I ['].rct' frood on top of sections with open end of hood
trghtlv aqainst llue collar. Make sure flue collar gasket
r: in place. not broken, bent or folded.
) In:tall 5/ l6 x 2" carriage bolts, flat washers and
rt'qultrr nuts on both sides of boiler starting at back
>r'('tionjoint. continuing at each joint. See Figure I0.
'l-rehten
nuts.
'l F.rsten hood to sections and flue collar:
ir. Slide holddown clip over carriage bolt and flange on
frood. Finger-tighten 5/ 1
6" flanged nut on carriage
i;olt. See Figure IO. Repeat for each clip. Where
hood joint interferes with clip installation, do not
install clip.
b. Ir.rstall
and finger-tighten six 5/16'x l" flanged
bolts and flanged nuts joining hood assembly to
f'lue collar.
(. Clentercollectorhood,makingsureitistightagainst
l}-recollar. Evenly t.ighten nuts on holddown clips,
being careful not to distort hood.
d. Tighten six 5/16" x I" flanged
bolts and flanged
nuts on flue collar to 30 - 35 in.-lbs.
Overtightening bolts in flue col-
lector hood assemblywill cause
gasketmaterial to extrude, caus-
ing possible flue gas leakageand
carbonmonoxide
emissions.
resulting in severe personal
iniurv or death.
Check gas-tight seal of llue collector hood and flue
collar. Gas light seal must be maintained to
prer.ent possible flue gas leakage and
carbon monoxide emissions. resul-
ting in severepersonal injury or death.
a. Open clamper in llue 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, loosebolts or nuts, or
missing holdclown clips. Correct all conditions and
repeat step b. II rrnsealecl zrreasstill exist, contact
your Weil Mcl;rin clistributor or sales oflice before
continr-rin{ installation.
HOLDDOWN
CLIP
FtUE
COLLECTOR
NOOD
A
@*-
FLANGEDNUT
REcuLenr.rur
=--*-J>6
FLAT
WASHER
CARRIAGE
BOLT
___\__
--- ,o rrosECo\)
\ ,*r-,-,
r.rro
SEATING
ROPE
Holddown Clip Installation
Figure l0
l2

SectionD: Per-fiorm
Hydrostatic PressureTest
Prepare boiler:
l. Referto Control Tapping Tableand install:
a. tsoilerdrain (notfurnished).
b. Waterpressuregauge
-for testonly. Besuregauge
can handle test pressure- seestep I under "Make
test.
"
c. Air vent in upper tapping.
2. Plug remaining tappings.
Do not pressure test r.vith
anv controls
installecl. Dantage to control can oc-
cur.
Make test:
l. Fill boiler. Vent all air. For morc than lO minutes.
prcssure tesl.:
Steam boilers between 45 - 55 psi.
Water boilers I I /2 times working pressure.
@q 3:,
::i,ii:::iJ:'ilHT:i:1
:"'
exccssive pressure, resulting in severe
personal injury, death or subst.antial
properly damage.
2. Check for maintained gauge pressure and leaks. Repair
il'founcl.
tr@E f:f.ll':""'.nTxi',:::
;ff;::"11,1.
ing in subst:rntial property damitge.
EE@ :'J',Jl:i#:
ilfii:::i?,1ili,:l:tiit"*
- f,:ll;.'l
liilil1lii:'::llil;:Jllff
lil:,
pr()penv
rlirnrlrgt..
3. Drain boiler and remove air vent, boiler dr:rin. gauge
;t::.Ot"Ut liom tappings used for controls and accesso-
oPTtoNAL
t-t/2'
TAPPING
OPTIONAL
INSPECTION
TAPPINGS
CONTROL TAPPING TABLF
LOCATION stzE STEAM \^/ATER
ASkim Tapping
Primary Probe.type
Low \ /ater Cutoff
or
Additional
High Limit Control
B3" Steam Relief Valve Water Relief Valve
cl ICombination
High/Low Limit
Control
cr&c2 Primary Water
Level Control
(Float.type)
DI Alternate
Probe-type
Low \i/ater Cutoff
DI&D2 Back-up \ /ater
Level Control
(Float-type)
Float-type
Low \ y'ater Cutoff
EI Firing Rate Control
(When Used)
EI &E2 Gauge Glass
Fl & F2** 3/4" Try Cock Tappings
Gl"
Limit Control,
Operating
Control, Pressure
Gauge
Pressure-
Temperature
Gauge
Hr-r
/2" Boiler Drain Boiler Drain
KIExpansion Tank
Piping
or
Automatic Air Vent
P' I
Eack-up (ONLY)
Probe-rype Water
Level Control
(MM
PS80r-r20
ONLY)
* ll x 2 brrshing :urcl 2 phrg proviclecl with boiler.
** [3y special rcquest onlv.
*** nP' tapping not intended 1brprimary low water cutoff
.- ______'-------l 3^
NPT
RETURN
Front Section
Figure I I
Back Section
t3

Section
E:Connect
Water BoilerPiping
General water piping information:
. >\ rirnr rr'irtt'rsltpph' ancl return piping should be
::.ri.Lllr'clancl pipin€ connections attached to boiler
:,,-:r,r't'r.rcctir-rq
jacket or installing controls.
o l),,
11,i1
prpc ir.rtl-rrough
supply and out throttgh return.
1
1)r>
(r-cilles
reverse water flow through boiler that nrust
:i,,1
ltt' Ltsetl.
o \\'itt'rr three rveryrralvesarrc
used for lcmperature nlod
::i.rrron.ir-rstall
slow-openin$
(minimum lO-ininut.e)
'..rlvt's
anci
boiler
rnixing
pur-npto nrinimize
potential
of
:r,iit'rthcrnral shock.See
W-M tsulletinAE U402.
Install
piping:
:.-'.ill
pipinc.
its
shown
inFigurel2 bc'low
lbrsingleboilcrs.
:-r l5 li)rlltultiple
boilers.
Improperrlv pipecl systcnrs or tttrclcrsizccl
piping can contribr-rte to crral.ic boiler op-
er:rtion anclpossible boiler or systenr clzrm-
:rg('.
SYSTEM
SUPPLY
(FRONT
ONLY)
EXPANSION
TANK
supply and retutn piping:
accordingto tablesbelow.
For unknown flow rates, size
piping perTable
below,using 20oF.temperature rise through
boiler.
RECOMMENDED
MINIMUM
PIPESIZES
FORUNKNOWN FLOW RATES*
BOILER
MODEL
SUPPLY
PIPESIZE
A
RETURN
PIPESIZE
B
378 2" 2"
478 2-12" 2-1t2"
578-678 I3"
778-t278 4"
All pipingsizcsb:rsetl
ort20"F.temper:tlure
rise
throrrgh
boiler.
F-rtrknown flow rates or higher flow rate
thror-rgl-r
boiler, size piping per thble below.
F-lorvat higher velocities than
shorvn in Table below lbr pipe
sizc r':ur clzrmageboiler, caus-
inq srrbst irnli:rl properrly
rlirrrrlqt-.
RECOMMENOED MINIMUM PIPESIZES
FOR KNOvvN FLO\^/ RATES
\^/ATER
FLO\^/
RATE
GPM
SUPPLY
PIPESIZE RETURN
PIPESIZE
B
Upto 35 22"
36to 50 z-tt2 z-il2"
5l to
77 J3
78to 142 44"
b. Loi'ate t irt'ttlirlor ilt srtpph' pipitlg.
('. For retrrrn pipinq. Lrsc
lirll clianretcr
pipe for lO
tirnes thal cliunrt'ter
belorc nlakinfl any redr-tction.
Forcx:rrnyrle.
ii-l-int'h rettlrlt shor-rld
not bc reduced
any c'loscr
to boiler r('tr.trlltapping tharn
40 inches.
d. Install systcnt blos'-oll (clrain)
r':rlvc
in lowest part
of retum pipin!. ('los('
lo ltctilcr.ASME Size
require-
ments are shtxr.rt
iIr'I-able belou'.
ASME DRAIN VALVE SIZE
BOILER MODEL va|-vE
slzE
(rN.)
378
- 478 lt4
578- il78
t278 t-U4
I. Connect
a. Size
l)
,t
CHECK WATER
I',1ETER
IlANUAL
VALVE
PRESSURE
REDUCING
VALVE
(WHENUSED)
Water Boiler Piping
Figure12
ISOLATION
VATVE
5YSTEl.1
RETURN
:qONT
ORREAR)
l4

Section
E:
Connect
Water BoilerPiping coNT'D
2. Install expansion tank:
a. Closed Q,pe - connect to l " tapping "K" (rel'erto
Control Tapping Table, page l3). Use l" N.P.T.
piping. Any horizontal piping must pitch up toward
tank at least I inch per each 5 feet of piping.
b. Diaphrergm [pe - Refer to tank manufacturer's
literature for location. Install automatic air vent in
"K" tapping.
c. Connect cold water fill to expansion tank piping.
SeeFigrrre 12.Also shown are recommended valvcs
and water meter. when used. Water mcter will
detect added make-up water, inclicating lezrks in
svstem.
I']ipingfor nrrrltiple boilcrs (st:c Figurt-'13):
Calcul:rte only secondary piping circuit resistance.
Boiler resistance will be about equal to three 90-
degreeelborvsol'secondary pipe size.
Operate each boiler and its secondary pump from
EMCS system. Do not maintain boiler at predeter-
nrined'uv:rter
temperature.
Prirnarl'punrp GPM and head calculation should
not include secondary boiler circuits. Primary
pump can operate continuously during heating
sc'ason.
Q! Sir.'st'r'orrclary
boiler
punrpGPM
baseclon lbllow-
ing lornrrrl:rs:
(;IIOSS
OL'1-I'L'1'
I\ I}.I'I-t] = Cll'\1
TEMPERATURE RISE IN oF x irOo
NOTE: TEMPERATIJR-ERISE IN.F=
23OOF
- RETI,JRNWATER TEMPERATURE
@
@
(9/ Space 12"maximum or as closeas practical
Check valve.
Il:rrrrlvalve.
l'-xpirrrsiorrtrrnk(s).reliel-r'alvesand other accessories
irrc re'rllrirt'cl
lrut ttot shovu.n.
Multiple Water Boiler Piping
Figurel3
t5

Section
F:ConnectSteam Boiler Piping
General steam piping information:
o Hartlbrd l-oop piping arrangement and wet return are
reclr-rirecllbr steanr boilers.
o \liiinlain 2-l-inch minimum from waterline to bottom of
hcadcr (56- I /.1 liom bottom of section).
o \\'hen usir-rgcondensate receiver, feed pump musl be
cnc'rqizcd bv boiler-mounted pump controller.
Install
piping:
Install piping as shown on page I7 for singleboilers,page
l9 for
mullipleboilers.
Improperly piped systemsor undersized
piping can contribute to erratic boiler
operationand possible
boiler or system
darnage.Pipingsystemmust be installed
asshown,usingpipe sizesshown.Consult
localWeil-McLaindistributor or sales
ollicebelbre installing alternate piping.
Connect supply :rnd return pipit-tg:
:1. Scc 1:rblc
below:rnd:
I
) Sizt' lorc'eclconclens:rte retlrrn piping by ptlnrp.
2l Sizcgravitv conclensatereturn same as equal
izer "J" pipc size.
lt. Ir-rst:rllsvstenr dr:rir-r
.,':rlve
in lowest part of rclurn
piping close to boilcr. ASME sizerequiremenls are:
shown in Table. pagcrI4.
Conncct colcl water lill piping ersshown in Figure
14.Also shown are recomnlcnded valves and water
metcr. il'usecl.Water nreter will ck-'lecl.
acldedmake-
trp water, ir-rdit'atir-rgleaks in systenr.
COLD
WATER
FLL
TO
CONDENSATE
RETURNP1PING
ORCONDENSATE
RECEIVER
(sEEFrG.r8,
PAGEr8)
Cold Water FillPiping
Figure14
I'lANUAt
PRESSURE
REDUCING
VALVE
STEAM BOILER PIPESIZE
TABLE
BASEDON 2.PIPE STEAM SYSTEM
FIG.
NO. BOILER MODEL
*RISER
PIPESIZE
- IN. H
HEADER
tN.
t
A B ctN.
t5 378 3 3 2
t5 478 442
t5 578 442-U2
t6 678 3 l 42-U2
t5 778 4 4 4 2-tt2
t6 878 4 4 4 3
l6 978 4 4 6 3
t7 |078-|278 4 4 4 6 3
Based on ASHRAE Handbook recommendations, allowing 1/2 oz.
pressure drop per 100 leet ofpipe for dry return.
Based on ASHRAE Handbook recommendations, allowing 2 oz.
pressure drop per IOOfeet of pipe at 3.5 PSIG. Maintain minimunr
24" heishl from waterllne to header
t6

Section
F:ConnectSteam Boiler Piping coNT'D
,
HEADER
PIPE
SIZE
"H''
24"
t'1tN.'l
FULL
SIZE
ORREDUCING
ELBOW
EQUALIZER
PtPE
SIZE
"j"
RISERPIPE
SIZE
"A
RISER
SIZE
"8"
24"
t'4tN.'
FULLSIZE
OR
REDUCING
ELBOW
EQUALIZER
PrPES|ZE
"J
'
4'MlN.
TO
IOP
OF
PIPE
CLOSE
NIPPLE
'i*ou,r,
CONDENSAII
RETURN
*24" minimum from water lineto bottom of header
378
through 578
Steam Boiler PiPing
Figure
15
RISER
srzE
'c"
*24" minimum from water lineto bottom of header
678through
978
Steam Boiler PiPing
Figure
l6
SYSTE14
SUPPLY
FULL
SIZEOR
REDUCING
ELBOW
EQUALIZER
PIPESIZE
'J"
4"tltN
TO
TOP
OF
PIPE
BACK
OF
BOILER
t--'
CLOSE
NIPPLE
. GRAVITY
CONDENSATE
RETURN
.
closE
NIPPLE
.\ .GRAVITY
CONDENSATE
RETURN
*24" minimum from water lineto bottom of header
1078
through 1278
Steam Boiler PiPing
Figure
17
SYSTEM
SUPPLY
SYSTEI,l
SUPPLY
HEADER
PIPE
t7

SectionF:ConnectSteam Boiler Piping cot{T'D
C'ottclt-tts'rl
c pipiltg:
Satisllrc'ton'operation of anv steam heating system depends on adequate return of condensate to maintain steadt-u-ater
level. Avoid aclding excessive amounts ol raw make-up water. Where condensate return is not adequate. a low.rvater
crttoll'nitl-t pump control, cond:-nsate receiver, and condensate boiler feed pump should be installed. Refer to Figure l ir
lor pipine arndto Condensate Receiver Capacity Table for sizing.
SYSTEMCONDENSATE
RETURN
I
V
TO
EOILERCONDENSATE
REIURN
COLDWATER
FILL
PIPING
. SEEFIGI4.
PAGE16
@ totrol tsoLATtoNvALVE
STRAINER
FEEDPUI'.1P
CHECKVATVE
@
o
@
CondensatePipingto Boiler
Figure18
ATMOSPHERE
CONDENSATE RECEIVER
CAPACITY TABLE
BOILER
MODEL
l=B=R
GROSS
OUTPUT
LBS.
STEAM
PERHOUR
GALLONS
CONDENSATE
PERHOUR
MINIMUM CONDENSATE RECEIVERCAPACITY - GAL. RECOMMENDED
CONDENSATE FEED
PUMP
CAPACITY GPM
AT I5
PSI
t5MtN.
*
BOILER
OPERATION
30MtN.
*
BOILER
OPERATION
45MlN.
*
BOILER
OPERATION
60MtN.
+
BOILER
OPERATION
378 278 34 ll 2l ll 4l t.l
478 400 48 t5 29 44 58 t.6
578 521 63 t9 38 57 76 2.1
678 543 77 24 47 70 93 2.6
778 754 92 28 55 83 ill 3.1
878 886 r06 32 64 95 127 3.5
978 |
007 t2l 37 73 t09 t4s 4.0
I
078 | 129 t36 4l 82 t22 r63 4.5
It78 |250 t50 4S 90 t35 r80 4.8
1278 1372 t6s 50 99 t49 r98 5.4
t8
Maximum time to when condensate returns to boiler.

Section
F:ConnectSteam Boiler Piping coNT'D
)3. Multiple steam boiler piping with graviff condensate
returrr:
Install boiler feecl
pump or solenoid control on each
boiler with body mark at level indicated on page 23.
Use:
o Separate feed pumps and check valves lbr
each boiler, or ...
o Single I'eecl pump and separate solenoid valves
for ear:h boilcr.
Install combitration lloat and thermostaticr trap on
ezrch
boiler t.o
prt:vent llooclirlg of onc boiler while
other boiler is {lring. For 78 boilcr, install trap irt
skinr tapping (soc
pitgc 22). Clortrtect
fr:r1ls
ttr
condensate rcceivcr.
(D ) tnstall stopvalves perASME code
requirements
\_-/ and slow-opening automatic steam valveswhen
used.UseEMCSsystemto openautomatic steam
valve befbre firing burner.
( E ) Construct common supply drop header
with pipe
size at learst
same
size
aslargestboilerheader
size.
Use:
. EMCSsystemwith header-mountedpressure
control(s)
to sequcnce
boilcrs. OR
o Steampressurc controller.
(G ) tnstarll
dr-ain
lirte in common supplv drop hcader'
- Ut" tonrbittittiotr flo:rtantl thenrltlstatic trap ancl
clrain ttt cottcletts:ttc
rccciver.
(p Install l;oiler ltilling as shoun irl lloiler tn:rtrrtrtl.
Multiple Steam Boiler Piping
Gravity Condensate Return
Figure19
l9

Section
G: Install
Jacket
lnstall Jacket:
1. f)ackaqecl boilers - install top jacket panel.
'2. Non-packaQed boilers - refer to instmctions packed in
.j:rcket canon. The following must be complete before
.jat'kct is installed:
o ltoilerl-r'u'drost.aticallypressure-tested. Seepage 13.
o plr.res
lbr unused tappings installed. See Control
Tapl;ing 1'able. page 13.
supply and return piping installed. See
paqes l{
through 19.
cleanoutplates,flue collar and flue collectorhood
installed. See pages
I - 12.
SectionH: Pipe
Tankless
Heaters
To pipe tankless heaters:
l. Size ltiping no smaller than heater inlet arrd outlet.
2. Autonr:ltic mixing valve must be inst.allcd. See Figure
20. Follorv manulircturer's instructions to install.
ll. F-lou,
regulating valve ntust be installed. Size according
to conlinuous draw of heater. See Table below. Follow
nranulhcturer's instructions to install.
TANKLESSHEATER RATINGS TABLE *
TANKLESS
HEATER
MODEL CONTINUOUS
DRAW GPM
INLET
AND
OUTLET
TAPPINGS
78-24 6.5 3t4"
GPM hcatccl frorn 4O')Fto lzlOoF (lOOoli lcmperature
rise)
with 2OO0Fboiler water tentperature.
Continuous clraw no recovelv oeriod.
Operating control with small ad-iustable dilferential
scale is recommended. Install in tempererturc control
tapping in he:rter plate.
Multiple tanklcss heaters (see F-igtrre20):
a. Use colclwater supply header with individual rist'rs
to each healer. Size heaclerby increasing one pipt,
size lbr cach aclditional hcater.
ir. Use hot water outlet lre:rclerwith individual riscrs
to each healcr. Size heaclt:r by increasing onc lti1tt'
size lbr c:rch additionzrl heater.
c. Do rrot pipe nrultiple heaters in series.
In hard water areas, sollen cold domestic supply warcr
to heaters to prcvcnt lime build-up.
ALTERNATE
t.'
../ TOAUTOIlATIC
I'IIXINGVALVE
ANDPIPING
4.
5.
6.
Tankless Heater Piping
Figure 20
20
ALTERNATE