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)