Weil-McLain 94 Series User manual

for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners
For additional
information, refer to . .
Burner specification
and data sheets
(for burners pre-tested with
model 94 boilers)
• Installation
• Startup
• Maintenance
• Parts
Boiler Manual
94
Series 3
Water & steam boilers
Part No. 550-110-275/1018
This manual must only be used by a qualified
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.
INSTALLER Consider piping and installation when determining
boiler location.
Any claims for damage or shortage in shipment must be
filed immediately against the transportation company
by the consignee.
USER . . . . This manual is for use only by your qualified heating
installer/service technician. Boiler and burner must be
installed by a qualified service technician. We recom-
mend regular service by a qualified service technician,
at least annually.

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
2 Part No. 550-110-275/1018
Hazard Definitions
The terms defined below 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 installa-
tion, operation or maintenance that are im-
portant but not related to personal injury.
Controls:
One limit control is supplied with the
boiler. A second limit control must be
supplied by the installer (field installed)
to comply with current ASME Boiler and
Pressure Vessel Code, Section IV.
IMPORTANT
When calling or writing about the boiler, please provide:
• Boiler model number
• Series
• CP number
This information is located on the boiler label/nameplate.
Read before proceeding:
Read all instructions before installing. Fail-
ure 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 property damage.
Propane boilers only — Your propane
supplier mixes an odorant with the propane
to make its presence detectable. In some
instances, the odorant can fade and the gas
may no longer have an odor.
■ Propane gas can accumulate at floor
level. Smell near the floor for the gas
odorant or any unusual odor. If you
suspect a leak, do not attempt to light
the burner.
■ Use caution when attempting to light a
propane burner (or pilot burner). This
should be done by a qualified service
technician, particularly if flame out-
ages (or pilot outages) are common.
■ Periodically check the odorant level of
your gas.
■ Inspect boiler and system at least yearly
to make sure all gas piping is leak-tight.
■ Consult your propane supplier regard-
ing installation of a gas leak detector.
There are some products on the market
intended for this purpose. Your sup-
plier may be able to suggest an appro-
priate device.
Read before proceeding

Boiler manual: • Installation • Start-Up • Maintenance • Parts
3Part No. 550-110-275/1018
Contents
Before installing boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Set boiler in place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembling the block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Perform hydrostatic pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control tapping locations — water boilers . . . . . . . . . . . . . . . . . . . . . . 12
Control tapping locations — steam boilers . . . . . . . . . . . . . . . . . . . . . . 13
Connect water boiler piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connect steam boiler piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Complete block assembly & install jacket . . . . . . . . . . . . . . . . . . . . . . . 20
Pipe tankless heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install water boiler controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install steam boiler controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connect breeching and venting systems . . . . . . . . . . . . . . . . . . . . . . . 31
Install fuel piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Make final adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Handling ceramic fiber and fiberglass materials . . . . . . . . . . . . . . . . . . . 36
Maintenance and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
4 Part No. 550-110-275/1018
Installation must comply with —
1. State, provincial and local plumbing, heating and electrical codes.
2. Regulations of servicing utilities.
3. ASME Section IV, Low Pressure Boiler and Pressure Vessel Code.
4. National Fuel Gas Code, ANSI/NFPA 54, when applicable.
5. National codes where applicable.
Before selecting boiler location
1. Check for nearby connections to:
a. Fuel supply.
b. Electrical power.
c. System water or steam piping.
d. Venting systems — see page 31.
e. Combustion and ventilation air supply — see page 5.
2. Check area around boiler. 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 clearance around boiler
1. Provide minimum clearances to combustible materials:
• Boiler top — 24 inches.
• Boiler front — 48 inches.
• Boiler flue — 9inches.
• Boiler rear — 9inches.
• Boiler sides — 6inches.
• Single-wall vent pipe – 18 inches.
• Double-wall vent pipe – refer to vent pipe manufacturer's recom-
mendations for vent pipe clearances.
2. Boiler may be installed on combustible flooring.
3. See page 42 for boiler dimensions.
Flue pipe/breeching clearances take precedence over jacket
clearances. Follow local codes requirements for clearances.
Increase clearances if necessary.
4. Provide minimum clearances for servicing:
• Right side — for cleaning and for tankless heater insertion/re-
moval — 44 inches.
• Rear — for breeching — 50 inches.
• Allow sufficient space on remaining sides for cleaning, servicing
and burner installation. See burner literature for length and recom-
mended service clearances.
Lay a foundation, if needed
1. Floor construction and condition must be suitable for weight of boiler
when filled with water. See page 42 for approximate boiler operating
weight.
2. A level concrete or brick foundation, constructed per Figure 1 and
Figure 2 is required when:
a. A floor could possibly become flooded.
b. Non-level conditions exist.
c. Boiler must be raised for burner clearance.
Before installing boiler
Figure 1 Boiler foundation, when required —
always use steel strips as shown for
proper draw-up and alignment of
sections
Figure 2 Boiler foundation (see Figure 1)
(boiler sections flush with one end of
foundation, 4 inches from the other
end)
Boiler model
number Length, L1
(inches)
894 55
994 61
1094 67
1194 73
1294 79
1394 85
1494 91
1594 97
1694 103
1794 109
1894 115
1994 121
2094 127
2194 133
2294 139
2394 145
2494 151
2594 157
Height,
H
(inches)
Gun-type burner: 2inches min.
Horizontal rotary or air atomizing
burner: 7inches min.
Consult burner manufacturer for
required clearances if burner is not
supplied by Weil-McLain.

Boiler manual: • Installation • Start-Up • Maintenance • Parts
5Part No. 550-110-275/1018
Before installing boiler (continued)
Combustion and ventilation air openings
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.
Do not install an exhaust fan in boiler room. Incor-
rect burner operation can result.
When combustion and ventilation air enters
through side wall openings, ensure that the open-
ings comply with the requirements of Figure 3 and
Figure 4.
Opening sizes must comply with state, provincial or
local codes. In the absence of local requirements, use
the National Fuel Gas Code, ANSI/NFPA 54). The
following information is taken from ANSI/NFPA 54.
For details and information not addressed below,
refer to the standard.
Combustion air openings to inside
Required volume of interior spaces
ANSI/NFPA 54 allows combustion air to be supplied through openings
to interior spaces if the volume of the connected interior spaces
meets the minimum volume required by the standard.
The minimum volume of interior spaces can be taken as 50 cubic feet
per 1,000 Btuh of all appliances in the spaces, or the minimum volume
can be calculated using the formulas given in ANSI/NFPA 54. Excep-
tion: If the air infiltration rate for the spaces is known to be less than
0.40 air changes per hour, the minimum volume must be calculated
as specified in the standard.
Inside air opening sizes and locations
For spaces that provide the minimum volume required by ANSI/
NFPA 54, the air openings must be sized per the following:
Combining spaces on the same story — Each opening shall have
a minimum free area of 1 in2⁄1000 Btuh (2200 mm2 /kW) of the total
input rating of all appliances in the space but not less than 100 in2
(0.06 m2). One opening shall commence within 12 inches (300 mm)
of the top, and one opening shall commence within 12 inches (300
mm) of the bottom, of the enclosure. The minimum dimension of air
openings shall be not less than 3 inches (80 mm).
Combining spaces in different stories — The volumes of spaces
in different stories shall be considered as communicating spaces where
such spaces are connected by one or more openings in doors or floors
having a total minimum free area of 2 in2⁄1000 Btuh (4400 mm2 /kW)
of total input rating of all appliances.
Figure 3 Combustion and ventilation air
openings — Boiler room below grade
Figure 4 Combustion and ventilation air
openings — Boiler room partially or
completely above grade
Combustion air openings to
outside
Outdoor combustion air can be taken through per-
manent openings (TWO or ONE), as described in the
following. The minimum dimension of air openings
shall not be less than 3 inches (80 mm).
Outside openings: TWO permanent openings
method
Two permanent openings, one commencing within
12 inches (300 mm) of the top and one commencing
within 12 inches (300 mm) of the bottom of the enclo-
sure shall be provided. The openings shall communicate
directly, or by ducts, with the outdoors or spaces that

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
6 Part No. 550-110-275/1018
Before installing boiler (continued)
freely communicate with the outdoors, as follows:
• Where directly communicating with the outdoors or
where communicating to the outdoors through vertical
ducts, each opening shall have a minimum free area of
1 in2⁄4000 Btuh (550 mm2/kW) of total input rating of
all appliances in the enclosure.
• Where communicating with the outdoors through hori-
zontal ducts, each opening shall have a minimum free
area of 1 in2⁄2000Btuh (1100 mm2 /kW) of total input
rating of all appliances in the enclosure.
Outside openings: ONE permanent opening method
One permanent opening, commencing within 12 inches
(300 mm) of the top of the enclosure, shall be provided. The
appliance shall have clearances of at least 1 in. (25 mm) from
the sides and back and 6 inches (150 mm) from the front of the
appliance. The opening shall directly communicate with the
outdoors or shall communicate through a vertical or horizontal
duct to the outdoors or spaces that freely communicate with the
outdoors and shall have a minimum free area of the following:
(1) 1 in2⁄3000 Btu/hr (700 mm2per kW) of the total input rating
of all appliances located in the enclosure, and . . .
(2) Not less than the sum of the areas of all vent connectors in
the space.
Combustion air — combination indoor
and outdoor openings
ANSI/NFPA 54 allows combustion air to be taken from a com-
bination of openings to outside and to interior spaces. Follow all
requirements of the standard to determine the minimum volume
of interior spaces and to calculate minimum sizes of openings.
Engineered Installations
Engineered combustion air installations shall provide an ad-
equate supply of combustion, ventilation, and dilution air and
shall be approved by the authority having jurisdiction.
Mechanical Combustion Air Supply
Where all combustion air is provided by a mechanical air supply
system, the combustion air shall be supplied from outdoors at
the minimum rate of 0.35 ft3/minute per 1000 Btuh (0.034 m3/
min per kW) for all appliances located within the space.
• Where exhaust fans are installed in the building, addi-
tional air shall be provided to replace the exhausted air.
• Each of the appliances served shall be interlocked to the
mechanical air supply system to prevent main burner
operation where the mechanical air supply system is not
in operation.
• Where combustion air is provided by the building’s me-
chanical ventilation system, the system shall provide the
specified combustion air rate in addition to the required
ventilation air.
Louvers, Grilles, and Screens.
The required size of openings for combustion, ventilation, and
dilution air shall be based on the net free area of each opening.
Where the free area through a design of louver or grille or screen
is known, it shall be used in calculating the size opening required
to provide the free area specified.
Where the louver and grille design and free area are not known,
it shall be assumed that wood louvers will have 25 percent free
area, and metal louvers and grilles will have 75 percent free area.
Non-motorized louvers and grilles shall be fixed in the open
position.
Minimum screen mesh size
Screens shall not be smaller than ¼ inch mesh.
Motorized louvers
Motorized louvers shall be interlocked with the appliance so they
are proven in the full open position prior to main burner ignition
and during main burner operation. Means shall be proved to
prevent the main burner from igniting should the louver fail to
open during burner startup, and to shut down the main burner
if the louvers close during burner operation.

Boiler manual: • Installation • Start-Up • Maintenance • Parts
7Part No. 550-110-275/1018
Set boiler in place
Do not raise or move assembled sections
using a jack or forklift. This could cause
the sections to shift, resulting in leaks.
Figure 5 Section assembly lifting weights
Boiler
model
number
Approximate
lifting
weight
(pounds)
Minimum
sling length —
(from crane hook to
boiler lifting lugs)
894 8600 3' 6"
994 9500 3' 6"
1094 10300 4' 0"
1194 11200 4' 6"
1294 12000 5' 0"
1394 12800 5' 0"
1494 13700 5' 0"
1594 14500 5' 0"
1694 15400 5' 0"
1794 16200 5' 0"
1894 17100 5' 0"
1994 17900 5' 6"
2094 18700 5' 6"
2194 19800 7' 6"
2294 20600 7' 6"
2394 21500 7' 6"
2494 22400 8' 0"
2594 23200 8' 0"
Ensure the equipment and cables used for lifting are
designed to handle the load. See Figure 5 for approximate
weights of model 94 section assemblies. Failure to comply
can result in severe personal injury, death or substantial
property damage.
The boiler contains ceramic fiber and fiberglass materials.
Use care when handling these materials per instructions
on "Handling ceramic fiber and fiberglass materials,"
page 36 of this manual. Failure to comply could result
in severe personal injury.
For packaged boiler or assembled block
assembly:
1. Packaged boilers only — Remove top jacket panels. Set aside until
after boiler is piped.
2. Remove lag screws from shipping rails.
3. Remove boiler from skid. Cables are already attached to block as-
sembly. See Figure 5 for lifting weight.
• 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.
4. Place ¼" x 3" steel plates on floor or foundation, spaced 51 inches
apart, as shown in Figure 1, page 4.
5. Place boiler in final position. Place boiler on foundation (if used)
as shown in Figure 1, page 4.
6. Level boiler. Shim under legs if necessary.
7. 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.
8. Inspect block assembly for disjointed sections.
a. Check inside section assembly for any light passing through
unsealed areas.
b. Mark all unsealed areas.
c. At unsealed areas, check for:
• Damaged gaskets.
• Sealing rope not in place.
• Loose bolts or nuts.
d. Correct all conditions and repeat step b. If unsealed areas still
exist, contact your Weil-McLain distributor or sales office
before continuing installation.
9. Check gas-tight seal of flue collector hood 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.
10. Proceed to "Perform hydrostatic pressure test," page 11.

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
8 Part No. 550-110-275/1018
Assembling the block
Sections are top heavy. Unbolted sections may fall if not
supported, resulting in severe personal injury or death.
Prepare the back section first
1. Place ¼" x 3" steel plates on the floor or foundation, spaced 51 inches
apart, as shown in Figure 1, page 4.
2. Apply
1⁄8" continuous bead of sealing rope adhesive in sealing rope
grooves around section perimeter and around flueways — see Figure 6.
Do not get any adhesive on the machined port surfaces.
Place sealing rope in grooves
1. Place
5⁄8" coated and uncoated sealing rope in the rope grooves as shown
in Figure 6.
2. See WARNING below — place coated rope and uncoated rope as
described.
3. Around curves, grasp rope at 1" intervals and push together. Do not
stretch the rope.
The boiler is supplied with TWO types of section sealing
rope — uncoated and coated with a narrow uncoated strip.
Use the uncoated rope only on the flueways as shown in
Figure 6.
Use the coated rope around the perimeter and around the
upper nipple port as shown in Figure 6. The uncoated side
of the rope must be pressed into the adhesive as shown in
order to obtain a proper adhesion.
DO NOT pre-cut rope for sections. Cut rope as each section
is placed.
A gas-tight seal must be maintained to prevent possibility
of flue gas leakage and carbon monoxide emissions, causing
severe personal injury or death.
Do not use petroleum-based cleaning or sealing com-
pounds in boiler system. Severe damage to system com-
ponents can result, causing substantial property damage.
Install nipple port sealing rings
1. Remove any grit from port machined surfaces with clean rag.
2. Place 9" and 6" sealing rings in appropriate port openings as shown in
Figure 6, page 8. If sealing ring slips out of groove, stretch ring gently
for several seconds, then reposition in groove.
3. Apply a continuous bead of silicone sealant no larger than 1⁄16" around
entire outside edge of the outer machined surface of the port. See Fig-
ure 7. Do not apply silicone sealant on, next to or under sealing ring.
Figure 6 Sealing rope installation

Boiler manual: • Installation • Start-Up • Maintenance • Parts
9Part No. 550-110-275/1018
Assembling the block (continued)
Figure 7 Applying silicone sealant around outsides of sealing
rings (shown on 94 intermediate section upper nipple
port)
Figure 8 Sealing ring installation and port alignment, typical
Weil-McLain cast iron section nipple port
Silicone sealant applied as specified above
prevents unburned oil vapors from coming
in contact with sealing ring. Vapor con-
tact can damage rings, resulting in severe
damage to boiler and substantial property
damage.
Raise the rear section upright
1. Hoist the back section upright.
2. Move rear section into position on the steel rails. The
section should be 4 inches from the end of the founda-
tion (if used) as shown in Figure 1, page 4.
3. Block under the flueway outlet to hold the rear section
upright in plumb position.
The back section must be plumb before in-
stalling other sections to ensure the block will
assemble correctly.
4. The blocking under the flueway can be removed later,
after several intermediate sections have been attached
and the assembly is stable.
5. Install intermediate sections and front section as de-
scribed on the following.
Install intermediate sections
1. Remove and discard 3⁄8" diameter shipping tie rods.
2. Remove grit from port machined surfaces with clean
rag. Also remove grit from tapped holes in all sections.
Do not use petroleum-based cleaning or
sealing compounds in boiler system. Severe
damage to system components can result,
causing substantial property damage.
3. Position intermediate section so aligning lugs fit into
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. Oil threads on (4) 5⁄8" x 11" draw rods. Install washer
and nut on end to be tightened. Use nut only on
other end.
b. Uniformly draw sections together, starting at
washer/nut end.
Important — Leave an equal amount of thread
on each end of the draw rod. This is needed
to allow securing the jacket support brackets
in place. The draw rods must not extend past
the face of the front or back section, or they
will interfere with the jacket.
c. Draw rods should be torqued to a range of 100 to
120 ft-lbs. Do not back off draw rods.
d. Metal-to-metal contact will be achieved around port
openings. See Figure 8.If gap occurs, it should be no
greater than .032". Check with feeler gauge.

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
10 Part No. 550-110-275/1018
Figure 9 Section arrangement (location of TI and SI sections, numbered from REAR to FRONT of block assembly)
Boiler
W= water
S= steam
Placement of special intermediate sections (TI and SI)
[numbering from REAR to FRONT, beginning with rear section as section number 1]
TI sections
with tankless coil openings
SI sections
with supply
tappings
# of coils ——
>12 3 4 5 6 7 8
894 W or S 5 5, 7 3, 5, 7 — — — — — —
994 W or S 6 6, 8 2, 4, 6 2, 4, 6, 8 — — — — —
1094 W or S 4 2, 4 2, 4, 7 2, 4, 7, 9 — — — — —
1194 W or S 4 2, 4 2, 4, 8 2, 4, 8, 10 — — — — —
1294 W or S 4 2, 4 2, 4, 9 2, 4, 9, 11 2, 4, 7, 9, 11 — — — —
1394 W or S 5 3, 5 3, 5, 10 3, 5, 10, 12 3, 5, 8, 10, 12 — — — —
1494 W or S 6 4, 6 2, 4, 6 4, 6, 11, 13 2, 4, 6, 11, 13 2, 4, 6, 9, 11, 13 — — —
1594 W or S 6 4, 6 2, 4, 6 4, 6, 12, 14 2, 4, 6, 12, 14 2, 4, 6, 10, 12, 14 — — —
1694 W or S 6 4, 6 2, 4, 6 4, 6, 13, 15 2, 4, 6, 13, 15 2, 4, 6, 9, 11, 13 2, 4, 6, 9, 11, 13, 15 — —
1794 W or S 7 5, 7 3, 5, 7 5, 7, 14, 16 3, 5, 7, 14, 16 3, 5, 7, 10, 12, 14 3, 5, 7, 10, 12, 14, 16 — —
1894 W or S 8 6, 8 2, 4, 6 2, 4, 6, 8 2, 4, 6, 8, 15 2, 4, 6, 8, 15, 17 2, 4, 6, 8, 11, 13, 15 2, 4, 6, 8, 11, 13, 15, 17 —
1994 W or S 6 4, 6 2, 4, 6 4, 6, 9, 11 2, 4, 6, 9, 11 2, 4, 6, 9, 11, 16 2, 4, 6, 9, 11, 16, 18 2, 4, 6, 9, 11, 14, 16, 18 —
2094 W or S 6 4, 6 2, 4, 6 4, 6, 10, 12 2, 4, 6, 10, 12 2, 4, 6, 10, 12, 17 2, 4, 6, 10, 12, 17, 19 2, 4, 6, 10, 12, 15, 17, 19 —
2194 W 6 4, 6 2, 4, 6 2, 4, 6, 9 2, 4, 6, 9, 11 2, 4, 6, 9, 11, 13 2, 4, 6, 9, 11, 13, 16 — 18, 20
2294 W 6 4, 6 2, 4, 6 2, 4, 6, 10 2, 4, 6, 10, 12 2, 4, 6, 10, 12, 14 2, 4, 6, 10, 12, 14, 17 — 19, 21
2394 W 6 4, 6 2, 4, 6 2, 4, 6, 9 2, 4, 6, 9, 11 2, 4, 6, 9, 11, 13 2, 4, 6, 9, 11, 13, 15 2, 4, 6, 9, 11, 13, 15, 18 20, 22
2494 W 8 6, 8 2, 4, 6 2, 4, 6, 8 2, 4, 6, 8, 12 2, 4, 6, 8, 12, 14 2, 4, 6, 8, 12, 14, 16 2, 4, 6, 8, 12, 14, 16, 19 21, 23
2594 W 8 6, 8 2, 4, 6 2, 4, 6, 8 2, 4, 6, 8, 11 2, 4, 6, 8, 11, 13 2, 4, 6, 8, 11, 13, 15 2, 4, 6, 8, 11, 13, 15, 17 22, 24
2194 S 2 2, 9 2, 9, 11 2, 9, 11, 13 2, 9, 11, 13, 20 — — — 4, 6, 16, 18
2294 S 2 2, 10 2, 10, 12 2, 10, 12, 14 2, 10, 12, 14, 21 — — — 4, 6, 17, 19
2394 S 2 2, 9 2, 9, 11 2, 9, 11, 13 2, 9, 11, 13, 15 2, 9, 11, 13, 15, 22 — — 4, 6, 18, 20
2494 S 8 2, 8 2, 8, 12 2, 8, 12, 14 2, 8, 12, 14, 16 2, 8, 12, 14, 16, 23 — — 4, 6, 19, 21
2594 S 8 2, 8 2, 8, 11 2, 8, 11, 13 2, 8, 11, 13, 15 2, 8, 11, 13, 15, 17 2, 8, 11, 13, 15, 17, 24 — 4, 6, 20, 22
If the boiler was ordered with tankless coils, the heaters must be located on the right hand side of the boiler. It is important to position the TI
sections (where used) in the exact location in the boiler section assembly as shown above so the heater knockout openings in the jacket side
panels will accommodate the heaters. If the TI sections and internal water heaters are not positioned in the boiler section assembly as shown
above, the installer must cut openings in the jacket side panels to accommodate the heaters.
e. If, for any reason, the gap around machined port open-
ing exceeds .032", check for rope extending from rope
grooves, dirt on port openings or sockets, or misaligned
lugs. If corrections are made and gap still exists, contact
your Weil-McLain distributor or sales office before con-
tinuing installation.
After erecting first intermediate section, check
both sections for plumb. Repeat the check as each
additional section is installed. Failure to plumb sec-
tions can cause misaligned piping and breeching,
possibly resulting in property damage.
5. Repeat steps 1-5 for all remaining sections. NOTE — use 5⁄8"
x 10" draw rods between intermediates.When used,install TI
(tankless intermediate) and SI (supply intermediate) sections
in the positions shown in Figure 9, page 10.
6. 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.
7. Install remaining intermediate sections and front section
using the same procedure.
If using tankless heater (TI) sections
• Install tankless heaters and gaskets or heater cover plates
and gaskets.
• Use
3⁄8" x 3⁄4"studs, washers and nuts.
Assembling the block (continued)

Boiler manual: • Installation • Start-Up • Maintenance • Parts
11Part No. 550-110-275/1018
Perform hydrostatic pressure test
Install boiler connections
894 – 1294 W
1. Secure supply elbow and gasket to front section and supply
outlet cover plate and gasket to back section.
• Use
5⁄8" x 3" studs, nuts, and washers.
• Thread flat end of stud into section.
2. Secure 6" NPT return opening counter flange and gasket to
back section using ¾" x 2" cap screws and washers.
1394 – 2094 W
1. Secure supply elbow and gasket to front section.
2. Use
5⁄8" x 3" studs, nuts, and washers.
3. Thread flat end of stud into section.
4. Secure supply outlet cover plate and gasket to back section.
5. Use
5⁄8" x 1¾" bolts.
6. Secure 8" pipe with standard 8" flange (not furnished) and
gasket (furnished) to back section. Use ¾" x 2" cap screws
and washers (furnished).
2194 — 2594 W
1. Secure outlet cover plate with 3 holes (¾" tapping on top)
and gasket to front section.
2. Secure outlet cover plate with 2 holes and gasket to back
section.
3. Use
5⁄8" x 1¾" bolts.
4. Secure 10" supply outlets and gaskets on top of "SI" sections.
• Supply outlet should have 1¼" tapping facing front.
• Use
5⁄8" x 3" studs, nuts, and washers.
5. Secure 10" flanged return adapter and gasket to back section
using ¾" x 2" hex head cap screws and washers.
894 S
1. Secure supply elbow and outlet gasket to front section and
supply outlet cover plate and gasket to back section.
• Use
5⁄8" x 1¾" bolts.
2. Secure 6" return opening counter flange and gasket to back
section. Use ¾" x 2" cap screws and washers.
994 — 2094 S
1. Secure supply elbows and outlet gaskets to front and back
sections.
• Use
5⁄8" x 3" studs, nuts and washers.
• Thread flat end of stud into section.
2. Secure 6" NPT return opening counter flange and gasket to
back section. Use ¾" x 2" cap screws and washers.
2194 — 2594 S
1. Secure outlet cover plates and gaskets to front and back
sections.
• The ¾" tappings in plates should be at top.
• Use
5⁄8" x 1¾" bolts.
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.
• Use
5⁄8" x 3" studs, nuts, and washers.
3. Secure 6" NPT return opening counter flange and gasket to
back section using ¾" x 2" hex head cap screws and washers.
Prepare boiler and test:
1. See Figure 10 (water boilers) or Figure 11 (steam boilers) for
tapping locations.
2. Install water pressure gauge — for test only. Be sure gauge
can handle test pressure — see step 8 for required test pres-
sure. Gauge range should be at least 1.5 times the test pres-
sure. Install the pressure test gauge in the tapping specified
in Figure 10 (water boilers) or Figure 11 (steam boilers).
3. Install an air vent in an upper tapping.
4. On front section: Install 3" close nipples and caps in washout
tappings.
5. On rear section: Install drain valve (furnished by installer)
in one of the washout tappings. (Verify drain valve size per
Figure 15, page 15.) Install 2" x 21⁄2" nipple and cap in the
other washout tapping.
6. Plug or use blind flanges on remaining tappings.
Do not pressure test with any control installed.
Damage to control can occur due to overpressure.
7. Fill the boiler with water. Vent all air.
8. Pressure test at least 10 minutes at a pressure not less than
the following:
a. Steam boiler: Between 45 and 55 psig.
b. Water boiler: 1½ times maximum allowable working
pressure (MAWP) stamped on the boiler nameplate,
located on boiler jacket front panel.
Do not exceed above test pressures by more than
10 psig.
Do not leave boiler unattended. Cold water fill
could expand and cause excessive pressure, result-
ing in severe personal injury, death or substantial
property damage.
9. Check for maintained gauge pressure and leaks. Repair if
found.
Leaks must be repaired at once. Failure to do so
can damage boiler, resulting in substantial property
damage.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to
system components can result, causing substantial
property damage.
10. Drain boiler and remove air vent, boiler drain and gauge.
11. Remove plugs from tappings that will be used for controls
and accessories.

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
12 Part No. 550-110-275/1018
Control tapping locations — water boilers
Figure 10 Model 94 water boiler control tappings
Item # Function Size
(Inches
NPT)
J1 PRESSURE TEST GAUGE — REMOVE AFTER
HYDROSTATIC TEST ½
J1 Temperature control or limit ½
J2 & J5 PLUG these tappings — not used on water boilers ½
M3 Probe-type low water cutoff 1
M1 + M2 Float-type low water cutoff or LWCO/feeder
combination 1
M3 + M4
P1 or R1 Temperature control or limit 3
S1 P/T gauge or temperature gauge ¾
T1 or T2 Temperature control or limit — or —
Air vent piping to compression tank 1¼
U1 & U2
Pressure relief valve(s):
894–2094: Install relief valve in one tapping and plug
the other tapping
2194–2594: Install a relief valve in each tapping
(2 relief valves required on these boilers)
2
V1 Temperature control or limit 4
W1 or W2 Temperature control or limit — or —
P/T gauge or temperature gauge ¾
X1 or X2 Temperature control or limit — or —
Air vent piping to compression tank 1¼
Y1 & Y2 PLUG this tapping — unless needed for a control 3⁄8
Z1 or Z2 Cleanout tappings — Front section — Install 2" NPT
close nipple and 2" NPT cap in each cleanout tapping 2
Z3 or Z4
Cleanout or drain tappings — Rear section —
Install drain valve in one tapping; install 2" NPT x 2½"
length nipple and 2" NPT cap in the other
2
—Low limit control (when using tankless heaters) —
locate in control tapping on one of the tankless heaters —
Controls and fittings must not
obstruct cleanout openings or
prevent required access to the
boiler or components.

Boiler manual: • Installation • Start-Up • Maintenance • Parts
13Part No. 550-110-275/1018
Control tapping locations — steam boilers
Figure 11 Model 94 steam boiler control tappings
Item # Function Size
(Inches
NPT)
J1 PRESSURE TEST GAUGE — REMOVE AFTER
HYDROSTATIC TEST ½
J1 + J5 Gauge glass ½
J2 PLUG this tapping — not used ½
M3 PLUG this tapping — not used 1
M1 + M2 Float-type low water cutoff, LWCO/pump control or
LWCO/feeder combination 1
M3 + M4
P1 Skim tapping 3
P2 Steam pressure relief valve 3
R1 Skim tapping 4
R2 Steam pressure relief valve 4
S1 Steam pressure gauge — or —
Pressure controls (limit, operating, etc.) ¾
S2 Pressure controls (limit, operating, etc.) ¾
T1 or T2 Pressure controls (limit, operating, etc.) 1¼
T3 or T4 Steam pressure gauge — or —
Pressure controls (limit, operating, etc.) 1¼
U1 or U2 Steam pressure relief valve — Install relief valve in
one tapping and plug the other 2
V1 or V2 Steam pressure relief valve — or —
Skim tapping 4
W1 or W2 Steam pressure gauge — or —
Pressure controls (limit, operating, etc.) ¾
W3 or W4 Pressure controls (limit, operating, etc.) ¾
X1 & X2 PLUG these tappings — not used 1¼
X3 & X4 PLUG these tappings — not used 1¼
Y1 & Y2 Try cocks 3⁄8
Z1 or Z2 Cleanout tappings — Front section — Install 2" NPT
close nipple and 2" NPT cap in each cleanout tapping 2
Z3 or Z4
Cleanout or drain tappings — Rear section —
Install drain valve in one tapping; install 2" NPT x 2½"
length nipple and 2" NPT cap in the other
2
—
Low limit temperature control (when using tankless
heaters) — locate in control tapping on one of the tankless
heaters
—
Controls and fittings must not
obstruct cleanout openings or
prevent required access to the
boiler or components.

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
14 Part No. 550-110-275/1018
Connect water boiler piping
General water piping information
1. System water supply and return piping should be installed and
piping connections attached to boiler before erecting jacket or
installing controls.
2. Do not pipe in through supply and out through return. This creates
reverse water flow through boiler that must not be used.
3. When installing in a system in which return water temperature can
drop below 140°F, apply the by-pass piping with by-pass pump as
shown in Figure 16, page 15.
4. When three-way valves are used for temperature modulation,
install slow-opening valves to minimize the potential of boiler
thermal shock.
Install piping
Install piping as shown in Figure 12, page 14 and Figure 16, page 15
(if applicable) for single boilers. For multiple boilers, see Fig-
ure 17, page 15.
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.
• For
known flow rates or higher flow rate (less than 20°F
temperature rise) through boiler, see Figure 13.
• For
unknown flow rates, size piping per Figure 15, page 15,
using 20°F temperature rise through boiler.
Flow at higher rates than shown in the tables in this
manual for given pipe sizes can damage the boiler, caus-
ing 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 4-inch
return should not be reduced any closer to boiler return tap-
ping than 40 inches.
d. Install system blow-off (drain) valve in lowest part of return
piping close to boiler. ASME minimum size requirements are
given in Figure 15, page 15.
2. Install expansion tank:
a. Closed type – connect to 11⁄4" tapping T1, T2 or X2 (see
Figure 10, page 12). Use 1" NPT piping. Any horizontal pip-
ing must pitch up toward tank at least 1 inch per each 5 feet
of piping.
b. Diaphragm type – Refer to tank manufacturer's literature for
location. Install automatic air vent in 11⁄4" tapping T1, T2 or
X2 (see Figure 10, page 12).
c. Connect cold water fill to expansion tank piping. Figure 12
shows typical piping when using a closed type tank. Connect
to the same location as the expansion tank connects to the
system when using a diaphragm type tank.
d. Also shown are recommended valves and water meter, when
used. Water meter will detect added make-up water, indicating
leaks in system.
Figure 12 Water boiler piping, typical
Figure 13 Recommended minimum pipe sizes for
known flow rates (note 1)
Water flow
rate, GPM
Supply pipe size
A
Return pipe size
B
up to 77 3" 3"
78 – 132 4" 4"
133 – 208 5" 5"
209 – 300 6" 6"
301 – 520 8" 8"
521 – 820 10" 10"
Note 1 High temperature rise through boiler is permissible when boiler
piping connections are sized per this table.
Intermittent flow at high velocities may damage any
boiler.

Boiler manual: • Installation • Start-Up • Maintenance • Parts
15Part No. 550-110-275/1018
Connect water boiler piping (continued)
Figure 14 Recommended minimum pipe sizes when flow rate is
not known (see Figure 12, page 14) (note 1)
Boiler
model
Supply pipe size
A
Return pipe size
B
894 5" 5"
994 – 1294 6" 6"
1394 – 2094 8" 8"
2194 – 2594 10" 10"
Note 1 Pipe sizes are based on a 20°F temperature rise through the boiler. For
applications with higher flow rates (lower temperature rise), determine
the flow rate and use Figure 13, page 14 to size the piping. DO NOT
use flow rates in excess of 520 GPM through 894–2094 or 820 GPM
through 2194–2594.
Figure 15 ASME drain valve size
Boiler
model
Minimum drain/blow-off
valve size
894 – 994 1¼"
1094 – 2194 1½"
2294 – 2594 2"
Piping multiple boilers
1. See Figure 16. (Expansion tanks, relief valves and other accessories
are required, but omitted from the illustration for simplicity.)
2. The boiler piping circuits are referred to as the secondary circuits
in the following.
3. The legend for Figure 16 and boiler pump sizing recommenda-
tions follow:
A Size boiler pump GPM based on the following:
a. Temp rise = High limit temp – Return water temp
b. GPM = Boiler Gross Output, Btuh
Temperature rise x 500
c. Calculate only secondary (boiler) piping circuit resistance. Al-
low for head loss through the boiler equal to three 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.
B Primary pump GPM and head calculation should not include
secondary boiler circuits. Primary pump can operate continuously
during heating season.
C Connection to primary circuit — Space 12" maximum or as close
as practical.
D Check valve.
E Hand valve.
Figure 16 By-pass piping for return water less
than 140°F
By-pass circulator sizing:
1. Size system circulator as required. Determine GPM
and head requirements.
2. Provide a by-pass circulator for EACH boiler. The flow
rate for each by-pass circulator will be:
Flow = ¼ x (System circulator GPM) ÷ (# of boilers)
3. All circulators must run at the same time.
4. Example: For a 1,000,000 Btuh single boiler, with
system temperature drop of 20°F:
• System GPM = 1,000,000 ÷ 20 ÷ 500 = 100 GPM
• By-pass GPM = ¼ x 100 GPM = 25 GPM
• Determine by-pass circuit head loss for pipe size
and fittings used.
5. In most applications, a standard booster pump should
be adequate.
Figure 17 Multiple water boiler piping

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
16 Part No. 550-110-275/1018
Connect steam boiler piping
Figure 18 Cold water fill piping
Figure 19 Condensate piping to boiler (see Figure 18
for cold water fill piping detail)
Boiler
model number
AHRI gross output
(lbs steam per hour)
Gallons condensate
per hour
Minimum condensate receiver capacity (gallons) (Note 1) Recommended condensate
feed pump capacity
GPM at 15 PSI
15-minute boiler
operation
30-minute boiler
operation
45-minute boiler
operation
60-minute boiler
operation
894 2,028 244 74 148 222 296 8.0
994 2,320 279 84 168 252 336 9.0
1094 2,612 314 95 190 285 380 10.5
1194 2,904 349 105 210 315 420 12.0
1294 3,190 383 115 230 345 460 13.0
1394 3,480 418 126 252 378 504 14.0
1494 3,770 453 136 272 408 544 15.0
1594 4,070 489 147 294 441 588 16.5
1694 4,360 524 158 316 474 632 17.5
1794 4,650 559 168 336 504 672 19.0
1894 4,940 594 179 358 537 716 20.0
1994 5,230 628 189 378 567 756 21.0
2094 5,520 663 199 398 597 796 22 0
2194 5,810 698 210 420 630 840 22.0
2294 6,100 732 220 440 660 880 24.0
2394 6,390 767 231 462 693 924 26.0
2494 6.680 802 241 482 723 964 27.0
2594 6,970 837 252 504 756 1,008 28.0
Note 1 — Maximum time to when condensate returns to boiler — the longer the time for condensate to return, the larger the receiver must be.
Figure 20 Condensate receiver capacity requirements
General steam piping information:
1. Hartford loop piping arrangement and wet return are required for
steam boilers. Use the Hartford loop for both pumped-return and
gravity-return systems.
2. Maintain 24-inch minimum from waterline to bottom of header
(863⁄4" from bottom of section).
3. When using condensate receiver, feed pump must be energized by
boiler-mounted pump controller.
4. Install piping:
a. Install piping as shown on page 17 through page 18 for single
boilers. See page 19 for additional requirements when piping
multiple boilers.
b. Return pipe sizing.
• Pumped return — Size return piping by pump.
• Gravity return — Size gravity return same as Hartford loop
equalizer pipe size.
c. Drain valve — Install system drain valve in lowest part of
return piping close to boiler. See Figure 15, page 15, for sizing.
d. Cold water fill piping — Connect cold water fill piping as shown
in Figure 18. Also shown are recommended valves and water
meter, if used. Water meter will detect added makeup water,
indicating leaks in system.
e. Condensate return piping:
• Satisfactory operation of any steam heating system depends
on adequate return of condensate to maintain steady water
level.
• Avoid adding excessive amounts of raw make-up water.
• Where condensate return is not adequate,a low water cutoff
with pump control, condensate receiver, and condensate
boiler feed pump should be installed.
• See Figure 19 for piping and Figure 20 for sizing.

Boiler manual: • Installation • Start-Up • Maintenance • Parts
17Part No. 550-110-275/1018
Connect steam boiler piping (continued)
Figure 21 Model 894 steam (1 riser)
Figure 22 Model 994 through 2094 steam (2 8-inch risers required)
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. 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
be 24 inches
The boiler header must always be at least 24 inches
above the water line, as shown in all steam boiler pip-
ing diagrams. Installing the pipe lower will result in
increased water carryover to the system, resulting in
potential serious damage to system components and
oxygen corrosion due to excess make-up water.
Hartford loop piping for all steam boilers
1. You must install the system supply pipe between the equalizer
elbow and the last boiler riser pipe connection to the header. This
assists in separating water from the steam as it turns upward into
the steam supply pipe.
2. Locate the top of the Hartford loop return nipple at least 4 inches
below the water line, as shown.
Pipe
Dimensions
Model Riser A Riser B Header H Equalizer J
994-1594 8" 8" 8" 4"
1694-2094 8" 8" 10" 4"
Pipe
Dimensions
Model Riser A Header H Equalizer J
894 8" 8" 4"
Drawing legend & notes
(Figure 21 through Figure 24)
1 Riser pipes (one for each supply outlet)
2 Horizontal pipes needed to offset the header to
allow for expansion and contraction of the header
3 Steam supply must be located between last riser
connection and equalizer elbow
4 Equalizer elbow — full size or reducing
5 Equalizer pipe
6 Close nipple at Hartford loop tee to reduce water
hammer potential
7 Condensate return line (gravity or pumped)
8 Pipe to provide 4 inches between water line and
top of Hartford loop return nipple
9 Boiler water line — all automatic water level con-
trols must be set to maintain this level
10 Minimum 24 inches between water line and bot-
tom of header
11 Offset tee

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
18 Part No. 550-110-275/1018
Connect steam boiler piping (continued)
Figure 23 Model 2194 through 2594 steam (2 10-inch risers required)
Drawing legend & notes
(Figure 21 through Figure 24)
1 Riser pipes (one for each supply outlet)
2 Horizontal pipes needed to offset the header to allow for expansion and contraction of the header
3 Steam supply must be located between last riser connection and equalizer elbow
4 Equalizer elbow — full size or reducing
5 Equalizer pipe
6 Close nipple at Hartford loop tee to reduce water hammer potential
7 Condensate return line (gravity or pumped)
8 Pipe to provide 4 inches between water line and top of Hartford loop return nipple
9 Boiler water line — all automatic water level controls must be set to maintain this level
10 Minimum 24 inches between water line and bottom of header
11 Offset tee
Pipe Dimensions Model Riser A Riser B Header H Equalizer J
2194-2594 10" 10" 12" 4"

Boiler manual: • Installation • Start-Up • Maintenance • Parts
19Part No. 550-110-275/1018
Figure 24 Multiple Steam Boiler Piping Gravity Condensate Return
Connect steam boiler piping (continued)
A Pipe as shown for gravity return systems, connecting point
Ato the wet gravity return.
• For pumped-return systems, install boiler water level
control on each boiler with body mark at level indicated
in Figure 38, page 30. Provide at point Aeither:
• Separate feed pumps and check valves for each boiler,
or . . .
• Single feed pump, with separate solenoid valve for each
boiler.
B For pumped-return systems, install a combination float and
thermostatic trap on each boiler to prevent flooding of one
boiler while other boiler is firing. Install trap in skim tapping.
Connect traps to condensate receiver.
Gravity-return systems are self-levelling if the wet returns are
piped to the common system wet return.
C Install boiler piping as shown in the preceding pages of this
manual.
D Install stop valves per ASME code requirements.
• For pump-return systems, if using automatic steam
valves, use only slow-opening automatic valves. Use
a Weil-McLain Boiler Control System (such as a BCP
panel) to open each steam valve automatically before
firing burner.
E Construct common supply drop header with pipe size at least
same size as largest boiler header size.
F Use:
• A Weil-McLain Boiler Control System (such as a BCP
panel) with header-mounted pressure control(s) to
sequence boilers, or . . .
• A steam pressure controller.
G Install drip line in common supply drop header.
• Gravity-return: Pipe drip line to wet return.
• Pumped-return: Use combination float and thermostatic
trap and drain to condensate receiver.
See page 18 for numbered
circle references.

Weil-McLain 94 Series 3 Water and steam boilers — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
20 Part No. 550-110-275/1018
Complete block assembly & install jacket
Before installing jacket
The boiler contains ceramic fiber
and fiberglass materials. Use care
when handling these materials
per instructions on page 36 of this
manual. Failure to comply could
result in severe personal injury.
The boiler must be pressure tested
before proceeding with jacket
installation. See page 11. Failure
to comply could result in severe
personal injury, death or substan-
tial property damage.
Read the following before install-
ing other controls and trim:
These parts MUST be ON the
boiler:
1. Plugs for unused tappings.
2. Supply and return piping and steam supply
header, including supply elbows or top sup-
ply adapters.
3. Tankless heaters (when used), tankless heater
cover plates (when used).
These parts MAY be on the boiler:
1. Burner mounting plate.
These parts MUST be OFF the
boiler:
1. Cleanout plates and cleanout doors.
2. Access panel.
3. Flue collar.
4. Breeching.
5. Burner.
6. Water or steam gauge.
7. Limit control and low water cutoff.
8. Gauge glass and gauge glass cocks, try cocks.
9. Drain cock.
10. Tankless heater piping (when used).
Burner mounting plate
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.
a. Thread two nuts on rounded end of ½" x 4¼" stud, locking them
together. Screw flat end of stud in one of six holes around opening.
b. Remove nuts from stud and save.
c. Repeat for remaining five studs.
d. Apply
1⁄8" continuous bead of rope adhesive in groove around
opening.
e. Position ½" sealing rope in groove. Overlap ends about 2 inches.
f. Install burner mounting plate with observation port at top of plate.
Use ½" washers and nuts.
Front observation plate
1. Install front observation port assembly over half-moon on burner
mounting plate:
a. Apply
1⁄8" continuous bead of rope adhesive in groove on assembly.
b. Position
3⁄8" sealing rope in groove, overlapping ends at least 1 inch.
c. Secure assembly to plate with 1⁄4" x 3⁄4" flat-head machine screws.
Cleanout and inspection tappings
1. If cleanout and inspection tappings were ordered, use 1½" brass coun-
tersunk plugs to plug openings.
2. If using "TI" sections, install tankless or storage heaters and gaskets, or
heater plates and gaskets. Use 3⁄8" cap screws.
Remove jacket parts from cartons and inspect
1. Locate jacket cartons.
2. Remove jacket parts from cartons as needed. Leave in cartons as long
as possible to avoid damage.
3. Inspect all parts before installing.
4. Jacket parts are in the boxes listed in Figure 25, page 21.
Prepare jacket panels for use
1. Determine from the control tapping table (Figure 10, page 12 or Fig-
ure 11, page 13) which of the knockout openings in the jacket panels
will be used.
2. To remove a knockout disc, bend one side inward until it can be
grasped with a pair of pliers; then, bend the disc back and forth until
it breaks loose.
The jacket side panels are reversible and can be placed
on either the left or right side of the boiler. If the boiler was
ordered with tankless coils (supplied with intermediate sec-
tions with tankless coil openings), the jacket side panels with
tankless coil knockouts must be properly positioned on the
right-hand side of the boiler ONLY.