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. 550-1 1-705/0600
78 78
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. 550-1 1-705
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
2
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
1a
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/ ,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/ inch mesh
Lock louvers in open position, or interlock
with equipment to prove open before
boiler operation.
Part No. 550-1 1-705 3
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
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
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
1b
Provide clearances for servicing
around boiler:
• Back, for breeching - 30 inches.
• Left side, for cleaning and tankless heater
removal - 3 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. 550-1 1-705
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
2a
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.
. 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 “ a: 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.
. Level boiler. Shim under skid angles, if
necessary.
5. 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.
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 “ a: Perform Hydrostatic Pressure
Test,” page 12.
Part No. 550-1 1-705 5
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
3a
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 .
.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
. 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.
.Place 7-1/2" and 3-1/2" sealing rings in
appropriate port openings. See Figure . If
sealing ring slips out of groove, stretch ring
gently for several seconds, then reposition in
groove.
Part No. 550-1 1-705
6
Cut off rope
even with
edges
Sealing rope
Cut off rope
even with
edge
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 -3/ " 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/ " 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/ " studs
and nuts.
Weil-McLain 78 Boiler For Gas Light Oil Gas/Light Oil Fired Burners
Assemble Block
3c
Part No. 550-1 1-705
8
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
3e
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.
. 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/ " 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/ " 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. 550-1 1-705
10
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

• Installation • Start-Up • Maintenance • Parts
Assemble Block
3f
Install flue collector hood assembly:
1. Place hood on top of sections with open end
of hood tightly against flue collar. Make sure
flue collar gasket is in place, not broken, bent
or folded.
2. Install 5/16" x 2" carriage bolts, flat washers
and regular nuts on both sides of boiler
starting at back section joint, continuing at
each joint. See Figure 10. Tighten nuts.
3. Fasten hood to sections and flue collar:
a. Slide holddown clip over carriage bolt and
flange on hood. Finger-tighten 5/16"
flanged nut on carriage bolt. See Figure 10.
Repeat for each clip. Where hood joint
interferes with clip installation, do not
install clip.
b. Install and finger-tighten six 5/16" x 1"
flanged bolts and flanged nuts joining hood
assembly to flue collar.
c. Center collector hood, making sure it is
tight against flue collar. Evenly tighten nuts
on holddown clips, being careful not to
distort hood.
d. Tighten six 5/16" x 1" flanged bolts and
flanged nuts on flue collar to 30 - 35 in.-lbs.
Overtightening bolts in flue
collector hood assembly will
cause gasket material to extrude,
causing possible flue gas
leakage and carbon monoxide
emissions, resulting in severe
personal injury or death.
.Check gas-tight seal of flue collector hood and
flue collar. 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.
Part No. 550-1 1-705 11
Regular nut
Flat washer
Carriage bolt
Boiler sections
Flat-stitched
sealing rope
Flue collector
hood
Holddown clip
Flanged nut
Figure 10 Holddown Clip Installation

General water piping information:
• System water supply and return piping should
be installed and piping connections attached to
boiler before erecting jacket or installing
controls.
• Do not pipe in through supply and out through
return. This creates reverse water flow through
boiler that must not be used.
• When three-way valves are used for
temperature modulation, install slow-opening
(minimum 10-minute) valves and boiler
mixing pump to minimize potential of boiler
thermal shock. See W-M Bulletin AE-8 02.
Install piping:
Install piping as shown in Figure 12 below for
single boilers, page 1 for multiple boilers.
Improperly piped systems or undersized piping
can contribute to erratic boiler operation and
possible boiler or system damage.
1. Connect supply and return piping:
a. Size according to tables below.
1)For unknown flow rates, size piping
per Table below, using 20°F. temperature
rise through boiler.
* All piping sizes based on 20°F. temperature
rise through boiler.
2)For known flow rates or higher flow
rate through boiler, size piping per Table
below. Flow at higher velocities than
shown in Table below for pipe
size can damage boiler, causing
substantial property damage.
b. Locate circulator in supply piping.
c. For return piping, use full diameter pipe for
10 times that diameter before making any
reduction. For example, a -inch return
should not be reduced any closer to boiler
return tapping than 0 inches.
d. Install system blow-off (drain) valve in
lowest part of return piping close to boiler.
ASME Size requirements are shown in
Table below.
Recommended Minimum Pipe Sizes
for Unknown Flow Rates*
Supply Return
Boiler Pipe Size Pipe Size
Model A B
378 2" 2"
478 2-1/2" 2-1/2"
578-678 3" 3"
778-1278 4" 4"
• Installation • Start-Up • Maintenance • Parts
Connect Water Boiler Piping
5a
Part No. 550-1 1-705 13
Recommended Minimum Pipe Sizes
for Known Flow Rates
Water Supply Return
Flow Rate Pipe Size Pipe Size
GPM A B
Up to 35 2" 2"
36 to 50 2-1/2" 2-1/2"
51 to 77 3" 3"
78 to 142 4" 4"
ASME Drain Valve Size
Boiler Model Valve Size (in.)
378-478 3/4
578-1178 1
1278 1-1/4
Cold
water fill
Expansion
tank
System
supply
(front only)
System return
(front or rear)
Manual
isolation
valve
Manual
isolation
valve
Pressure
reducing
valve
(when used)
Figure 12 Water Boiler Piping
Check
valve
Water
meter

• Installation • Start-Up • Maintenance • Parts
Connect Steam Boiler Piping
6a
General steam piping information:
•Hartford Loop piping arrangement and wet
return are required for steam boilers.
• Maintain 2 -inch minimum from waterline to
bottom of header (56-1/ " from bottom of
section).
• When using condensate receiver, feed pump
must be energized by boiler-mounted pump
controller.
Install piping:
Install piping as shown on page 16 for single
boilers, page 18 for multiple boilers.
Improperly piped systems or
undersized piping can contribute
to erratic boiler operation and
possible boiler or system
damage. Piping system must be
installed as shown, using pipe
sizes shown. Consult local Weil-
McLain distributor or sales office
before installing alternate piping.
1. Connect supply and return piping:
a. See table below and:
1)Size forced condensate return piping by
pump.
2)Size gravity condensate return same as
equalizer “J” pipe size.
b. Install system drain valve in lowest part of
return piping close to boiler. ASME size
requirements are shown in Table, page 13.
c. Connect cold water fill piping as shown in
Figure 1 . Also shown are recommended
valves and water meter, if used. Water meter
will detect added makeup water, indicating
leaks in system.
Part No. 550-1 1-705 15
* Based on ASHRAE Handbook recommendations, allowing 1/2 oz. pressure drop per 100 feet of pipe for dry return.
**Based on ASHRAE Handbook recommendations, allowing 2 oz. pressure drop per 100 feet of pipe at 3.5 PSIG.
Maintain minimum 2 " height from waterline to header.
Steam Boiler Pipe Size Table
Based on 2-Pipe Steam System
*Riser * *
Pipe Size - In. H J
Fig. Boiler Header Equalizer
No. Model A B C In. In.
15 378 3 3 2
15 478 4 4 2
15 578 4 4 2-1/2
16 678 3 3 4 2-1/2
16 778 4 4 4 2-1/2
16 878 4 4 4 3
16 978 4 4 6 3
17 1078-1278 4 4 4 6 3
Cold
water fill
Manual
isolation
valve Pressure
reducing valve
(when used)
Manual
isolation
valve
Water meter
Check
valve
To condensate
return piping or
condensate
receiver
(see fig. 18,
page 17)
Figure 14 Cold Water Fill Piping