Weil-McLain 94 Series User manual

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I. General Requirements
A. Furnish and install ( ) low pressure, wet base, cast iron sectional boiler(s) with power
burner(s) that pressurize the firebox and operate under forced and balanced draft.
B. Assemble and install boiler-burner unit(s) in compliance with manufacturers installation
instructions. All work must be done in a neat and workman like manner.
C. Weil-McLain (P)(A)(B) L, (P)(A)(B) G, (P)(A)(B) GL- ( )94-(W) (S)F boiler(s) with
burner(s) capable of burning natural gas at ( )” W.C. inlet pressure and/or No. 2 fuel oil.
1. (B) Boiler-burner unit Field assembled (standard).
2. (A) Boiler-burner unit with factory assembled sections (to size 21 only).
3. (P) Boiler-burner unit completely packaged and fire tested (to size 21 only).
4. Natural gas fired and/or No. 2 fuel oil.
5. Water or steam.
6. Forced or balanced draft.
D. Boiler(s) shall have I=B=R Hydronics Institute gross output(s) at 100% firing rate –
( ) MBH per boiler.
E. Boiler(s) shall be manufactured by ISO 9001 registered company to conform to Section
IV of the ASME Boiler and Pressure Vessel Code.
1. Individual sections (and section assembly) to be hydrostatically pressure tested at
factory in accordance with ASME requirements.
2. Maximum allowable working pressure 50 PSIG water and 15 PSIG steam cast as
part of section with ASME symbol (Water only: optional 80 PSIG stamped in
section in place of 50 PSIG).
F. Regulatory Requirements
1. Boiler(s) and controls to comply with applicable regulations.
2. Provide UL labeled burner(s).
3. Provide add option for local code(s) ie: MASS Code BAR
G. Submittals
1. Submit shop drawings and product data.
2. Submittal packet to include boiler (and burner) manufacturer descriptive literature,
installation instructions, operating instructions, and maintenance instructions.
II. Product
A. Acceptable boiler/burner manufacturer(s) include(s):
1.Weil-McLain only, as specified in Part 1, Paragraph C.
94 SERIES BOILER
SUGGESTED SPECIFICATIONS

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2. Other manufacturer(s) or other Weil-McLain boiler(s) must comply with
specifying engineer’s requirements, including:
a) Full intent of these specifications, and provide complete submittal
including literature, wiring diagrams, fuel piping diagrams, and a list of
similar installations.
b) Submittal to be presented to specifying engineer at least seven working
days for approval before bid opening. Substitutions are not permitted after
contract is awarded.
c) Burner(s) and Energy Management Control System(s) must be tested
and approved for installation with specified boiler by boiler manufacturer.
B. Boiler construction
•Boiler sections
•Assembled with short, individual draw rods.
•Cast with sealing grooves for high temperature sealing rope to assure
permanent gas-tight seal.
•Sealed water-tight by elastomer sealing rings, not cast iron nipples. Each port
opening is machined to completely capture sealing ring between sections.
•Must be hydro-wall design to provide completely water-cooled combustion
chamber.
•Provided with sufficient tappings to install required controls.
•Limited 10 year warranty against workmanship and defects to be in writing by
manufacturer.
C. Boiler(s)
•Provided with cast-in air elimination to separate air from circulating water.
•Provided with expansion tank tapping to divert separated air to expansion tank.
•Constructed to provide balanced water flow through entire section assembly
using single supply and return connections for water. No external headers are
necessary for water. Steam requires anexternal header 24” minimum from the
waterline to the bottom of the header.
•Designed with a low silhouette to provide maximum headroom.
•Furnished with insulated burner mounting plate having necessary holes and
tappings to mount burner. High temperature sealing rope is used to provide
permanent gas-tight seal between front section and plate.
•Furnished with two observation ports (one in front and one in back) to allow
visual inspection of the flame.
•Provided with cast iron flue collar with a built-in adjustable damper capable of
being locked into place after adjustment.
•High temperature sealing rope used to provide permanent gas-tight seal
between hood and section assembly.
•Furnished with cast iron cleanout plates to cover cleanout openings on the
front of the boiler(s).
•Elastomer sealing rings are to be used to provide permanent water-tight seal
between sections. Unlike cast iron or steel push nipples, the elasticity of the
seals fills any gaps caused by misalignment or expansion or contraction.

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•Shipped with insulated heavy gauge steel jacket(s) with durable powdered
paint enamel finish. Jacket designed to be installed after connecting supply and
return piping.
D. Tankless heaters or indirect water heaters
•Provide ( ) internal tankless water heater(s) inserted into the right hand side
of the tankless intermediate (TI) section in the opening provided. Allow 44”
minimum clearance on right side of boiler for cleaning and servicing. Tankless
openings must be on same side as the flue passage cleanout plates to
minimize space requirements.
E. Boiler foundation(s):
•Installer to construct needed support and level concrete foundation(s) where
boiler room floor is uneven or will not support the weight of the boiler(s).
F. Boiler trim:
1. All electrical components to be of high quality and bear the UL label.
a) Water boiler(s) controls furnished:
1) Combination low temperature limit (operating) and high temperature limit
control.
2) Low temperature limit set according to system design. High temperature
limit set at least 20°F higher than the low limit (240°F is the maximum
allowable water temperature).
3) Combination pressure-temperature gauge with dial clearly marked and
easy to read.
4) ASME certified pressure relief valve, set to relieve at 30 PSIG. Optional
relief valves available up to and including maximum allowable pressure.
Side outlet discharge type; contractor to pipe outlet to floor drain or near
floor, avoiding any area where freezing could occur.
b) Steam boiler(s) standard controls furnished:
1) Low pressuretrol (operating) and high pressuretrol set at maximum
pressure as a safety control.
2) Steam pressure gauge with dial clearly marked and easy to read.
3) Gauge cock water set with gauge glass, guards and aluminum water level
plate.
4) ASME certified pressure relief valve, set to relieve at 15 PSIG. Side outlet
discharge type; contractor to pipe outlet to floor drain or near floor,
avoiding any area where freezing could occur.
c) Low water cut-off for water or steam boiler(s):
1) Boiler(s) to be furnished with UL labeled low water cut-off with ASME
working pressure rating equal to the ASME rating of the relief valve.
2) Do not use quick-connect fittings on boiler(s).
3) Install cut-off according to manufacturer’s instructions.
4) Locate so burner shuts down if boiler water level falls below allowable
safe waterline (steam boilers, ¼” above bottom of gauge glass).
5) Steam boiler primary low water cut-off shall be a float type – auto reset.

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6) Steam boiler secondary low water cut-off shall be a float type – manual
reset.
III. Burner(s) construction, features and requirements:
1. Burner fuel supply system and burner installation to conform to burner
manufacturer’s installation instructions and applicable codes.
2. Burner motor characteristics: 120/60/1, 240/60/1, 208/60/3, 
240/60/3, 480/60/3.
3. Control characteristics 120/60/1.
4. Burner fuel – natural gas 4.0” W.C. minimum, No. 2 fuel oil.
5. Code(s) - standard boiler, CSD-1, FM, IRI
6. Burner(s) to have UL label(s) supplied by the burner manufacturer.
7. Burner(s) designed to ensure high efficiency and good performance under
forced draft conditions with 0.1” W.C. positive pressure at the flue collar.
8. Burner to be adjusted to provide 9.5 to 10.0% CO2for gas and/or 11.5 to 12%
CO2with zero smoke for oil firing.
9. Burner(s) manufactured by: Power-Flame, Gordon-Piatt.
10. Burner operating mode: on-off, low-high-off, low-high-low, 
modulating
A. Panel options – power on/fuel on light is standard on all burner(s) with panels.
1) Call For Heat
2) Ignition On
3) Pilot Failure
4) Low Water
5) Flame Failure
6) Silencing Switch
7) Control Fuse and Holder
8) Post Purge Timer
9) Alarm Bell
B. Start-up and Service
•The contractor shall obtain the services of a factory authorized agent to provide
burner light-off and adjustment. The start-up agent shall provide a burner light-
off report as written proof that the burner was adjusted to optimum
performance.
•Authorized: The agent shall provide a one year service warranty after start-up.
Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
http://www.weil-mclain.com
C-810(699)