Weil-McLain Series 4 User manual

Boiler Manual
!
WARNING
Installation and service of the boiler must be performed by a qualied installer or service technician.
Read all instructions, including this manual and all other information shipped with the boiler, before
installation or operation. Perform steps in the order given. Failure to comply could result in severe
personal injury, death or substantial property damage.
94
Steam Boiler - Series 4
For use with Gas, Light Oil, and Gas
with Light Oil Fired Burners
Manual Part Number 550-100-157/0523

2550-100-157/0523
 94  4 
Contents
Tools . . . . . . . . . . . . . . . . . . . . . . . . 4
Abbreviations . . . . . . . . . . . . . . . . . . . 4
- 
Safety Signals . . . . . . . . . . . . . . . . . . . 5
Please Read Before Proceeding . . . . . . . . . 5
Servicing a Boiler . . . . . . . . . . . . . . . . . . . . 5
Boiler Operation . . . . . . . . . . . . . . . . . . . . 6
Boiler Water. . . . . . . . . . . . . . . . . . . . . . . 6
Commonwealth of Massachusetts . . . . . . . . . . . 6
Freeze Protection Fluids . . . . . . . . . . . . . . . . 6
Damage from Water Contact . . . . . . . . . . . . . . 6
Frozen Water Damage . . . . . . . . . . . . . . . . . 6
- 
Prepare Boiler Location. . . . . . . . . . . . . . 7
Installation Compliance Requirements . . . . . . . . . 7
Checks Before Boiler Installation . . . . . . . . . . . . 7
Flooring and Foundation . . . . . . . . . . . . . . . . 8
Garage Installation . . . . . . . . . . . . . . . . . . . 8
Air Openings . . . . . . . . . . . . . . . . . . . . . . 8
Clearances . . . . . . . . . . . . . . . . . . . . . . . 9
Prepare the Boiler . . . . . . . . . . . . . . . . .10
Removing a Packaged Boiler from the Crate. . . . . 10
Removing a Preassembled Block from the Crate . . .11
Boiler Assembly . . . . . . . . . . . . . . . . . . 12
Assembling the Block. . . . . . . . . . . . . . . . . 12
Boiler Connections for Pressure Testing . . . . . . . 16
Perform Hydrostatic Pressure Test . . . . . . . . . . 16
Connect Steam Boiler Piping . . . . . . . . . . . . . 18
Steam Boiler Piping Guidelines. . . . . . . . . . . . 19
Burner Mounting Plate Installation . . . . . . . . . . 22
Front Observation Plate Installation . . . . . . . . . 22
Cleanout and Inspection Tappings . . . . . . . . . . 22
Jacket Installation Guidelines. . . . . . . . . . . . . 22
Jacket Parts Removal and Inspection . . . . . . . . 22
Preparing Jacket Panels for Use . . . . . . . . . . . 23
Installing Front and Rear Jacket Panels . . . . . . . 24
Install Side Panel Brackets and Splice Channels . . 24
Installing Side and Top Jacket Panels . . . . . . . . 24
Installing Front Cleanout Doors. . . . . . . . . . . . 26
Installing Front Cleanout Plates . . . . . . . . . . . 26
Installing the Flue Collar . . . . . . . . . . . . . . . 27
Installing the Back Access Door . . . . . . . . . . . 27
Tankless Heaters . . . . . . . . . . . . . . . . .28
Hot Water Precautions . . . . . . . . . . . . . . . . 28
Piping Tankless Heaters . . . . . . . . . . . . . . . 28
Steam Boiler Controls. . . . . . . . . . . . . . .29
Installing the Controls. . . . . . . . . . . . . . . . . 29
Ba󰀪e Assembly and Installation . . . . . . . . . .32
Boiler Ba󰀪e System . . . . . . . . . . . . . . . . . . . .32
Installing the 2nd Flue-Way Ba󰀪es . . . . . . . . . . . .33
Assembling the 3rd Flue-Way Ba󰀪es . . . . . . . . . . . 35
Installing the 3rd Flue-Way Ba󰀪es . . . . . . . . . . . . 37
Commonwealth of Massachusetts Installations. . 38
Venting and Combustion Air - General. . . . . .39
Code Compliance. . . . . . . . . . . . . . . . . . . 39
Combustion Air Contamination . . . . . . . . . . . . 39
Dual Fuel Venting Requirements . . . . . . . . . . . 39
Venting and Combustion Air Options . . . . .40
Existing Category I Vent System . . . . . . . . . . . 40
Test Procedure for Existing Vent System . . . . . . . 40
Room Air Openings . . . . . . . . . . . . . . . .41
Combustion Air Provision . . . . . . . . . . . . . . . 41
Sizing Combustion Air Openings . . . . . . . . . . . 41
Special Considerations . . . . . . . . . . . . . . . . 41
Breeching and Venting . . . . . . . . . . . . . .43
General Venting Information . . . . . . . . . . . . . 43
Construct Metal Breeching . . . . . . . . . . . . . . 43
Gas Venting Requirements — General. . . . . .44
General Gas Venting Information. . . . . . . . . . . 44
Engineered Vent System . . . . . . . . . . . . . . . 44
Types of Gas Venting Systems . . . . . . . . . . . . 45
Oil Venting Requirements. . . . . . . . . . . . .46
Using a Chimney . . . . . . . . . . . . . . . . . . . 46
Vent Piping Materials . . . . . . . . . . . . . . . . . 46
General Oil Venting Information . . . . . . . . . . . 47
Engineered Vent System . . . . . . . . . . . . . . . 47
Oil Venting System . . . . . . . . . . . . . . . . . . 48
Install Burner and Fill the System . . . . . . . . 49
Burner Installation . . . . . . . . . . . . . . . . . . 49
Wire the Burner and Boiler Controls . . . . . . . . . 49
Fill the Steam Boiler . . . . . . . . . . . . . . . . . 49
Fuel Piping . . . . . . . . . . . . . . . . . . . . . 50
Gas Piping . . . . . . . . . . . . . . . . . . . . . . 50
Fuel Oil Piping . . . . . . . . . . . . . . . . . . . . 50
Final Adjustments . . . . . . . . . . . . . . . . .51
Adjust the Burner and Damper Assembly . . . . . . 51
Skim Steam Boilers. . . . . . . . . . . . . . . . . . 52
Check the Boiler for Gas-Tight Seal . . . . . . . . . 52

3550-100-157/0523
94  4  
- 
Maintenance - General . . . . . . . . . . . . . .53
Handling Ceramic Fiber Materials . . . . . . . . . . 53
Perform Startup and Checkout . . . . . . . . . . . . 53
Annual Inspection . . . . . . . . . . . . . . . . .54
General Inspection Information . . . . . . . . . . . . 54
Inspect the Boiler Area . . . . . . . . . . . . . . . . 54
Inspect All Piping for Leaks . . . . . . . . . . . . . . 54
Inspect the Boiler Interior . . . . . . . . . . . . . . . . . . 54
Check Air Openings . . . . . . . . . . . . . . . . . 54
Boiler Service and Maintenance . . . . . . . . .55
Service and Maintenance Schedules. . . . . . . . . 55
Cleaning Heating Surfaces and Flue-ways . . . . . . 56
Cleaning the Water Side of the Boiler . . . . . . . . 56
Cleaning Float-Type Low Water Cut-o󰀨s . . . . . . . 56
Cleaning the Gauge Glass . . . . . . . . . . . . . . 57
Checking the Relief Valve . . . . . . . . . . . . . . 57
Troubleshooting — Priming or Foaming . . . . . . . 57
Seasonal Boiler Shutdown . . . . . . . . . . . . . . 58
Long-Term Boiler Shutdown . . . . . . . . . . . . . 58
- 
Miscellaneous Parts. . . . . . . . . . . . . . . .59
Ordering . . . . . . . . . . . . . . . . . . . . . .59
Replacement Parts . . . . . . . . . . . . . . . .60
Dimensions . . . . . . . . . . . . . . . . . . . .66
- 
Ratings . . . . . . . . . . . . . . . . . . . . . . .69
Maintenance Log . . . . . . . . . . . . . . . . .70
Installation and Service Certicate. . . . . . . . 71
Notes . . . . . . . . . . . . . . . . . . . . . . . . .71

4550-100-157/0523
 94  4 
Tools Needed Purpose
1/16" at blade screwdriver Wiring onto terminal blocks.
Phillips head screwdriver Jacket posts and channels
5/16" wrench or socket Sight glass and ba󰀪e assembly
11 mm wrench or socket Cover plate bolts
3/4" wrench or socket Burner mounting plate
15/16" wrench or socket Castings to castings tie rod nuts
1-1/16" wrench or socket Limit control
9/16" wrench Pressure and temperature gauge
Flat head screwdriver Sight glass
Pipe wrench Water piping and plugs
Multimeter Measurement readings on sensors
and electrical components
Manometer
(inclined or digital)
Measuring the gas pressure
coming to the boiler
Combustion analyzer
(digital preferred) Combustion testing
Contact thermometer Checking surface temperatures of
the heat exchanger and pipes
Abbreviation Description
AHRI Air-Conditioning, Heating, and
Refrigeration Institute
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
AWG American Wire Gauge
BTUH British Thermal Unit per Hour
CFM Cubic Feet Per Minute
CO Carbon Monoxide
CO2Carbon Dioxide
CP Consumer Protection
DHW Domestic Hot Water
HX Heat Exchanger
LWCO Low Water Cut-O󰀨
MAWP Maximum Allowable Working Pressure
MBH Thousands of Btuh
NFPA National Fire and Protection Agency
NIOSH National Institute for Occupational Safety
and Health
W.C. Water Column

Table 2 Common abbreviationsTable 1 Common tools needed
Tools

5550-100-157/0523
94  4  
1
2
3
4
5
6
7
8
This section is intended to provide safety information
for installers and users.
Section Contents
Safety Signals . . . . . . . . . . . . . . . . . . . . . 5
Please Read Before Proceeding . . . . . . . . . . . . 5

The following dened terms are used throughout this
manual to bring attention to the presence of hazards
or other important information.
DANGER
!
Danger indicates the presence of hazards that
will result in severe personal injury, death, or
substantial property damage.
!
WARNING
Warning indicates the presence of hazards that
can result in severe personal injury, death, or
substantial property damage.
CAUTION
!
Caution indicates the presence of hazards that
will or can result in minor personal injury or
property damage.
NOTICE
Notice indicates additional information that may be
related to property damage, but is not related to
personal injury.
IMPORTANT
Important indicates additional information that is
important, but is not related to personal injury or
property damage.

!
WARNING
Adhere to all following guidelines and
instructions in this section. Failure to adhere to
these guidelines can result in severe personal
injury, death, or substantial property damage.
Installer: Read all instructions, including this manual
and all other information shipped with the boiler,
before installation. Perform steps in the order given.
Consider piping and installation when determining
boiler location.
Write the Consumer Protection (CP) number and
serial number in the space provided on the Installation
and Service Certicate on page 71. The CP number
can be found on the boiler jacket.
Please include the boiler model number, CP
number, and serial number when calling or writing
about the boiler. The model number can be found on
the boiler rating label.
User: This manual is for use only by a qualied
heating installer or service technician. A qualied
service technician should inspect and service this
boiler at least once per year.
IMPORTANT
Any claims for damage or shortage in shipment
must be led immediately against the transportation
company by the consignee.
Servicing a Boiler
• To avoid electric shock, disconnect all electrical
supplies to the boiler before performing maintenance.
• To avoid a potential explosion, shut o󰀨 the fuel
supply to the boiler while servicing.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
• This boiler contains ceramic ber and berglass
materials. Refer to the warning and instructions on
page 53.



6550-100-157/0523
 94  4 
1
2
3
4
5
6
7
8

Boiler Operation
• Do not block ow of combustion or ventilation air
to boiler.
• Should overheating occur, or gas supply fail to
shut o󰀨, do not turn o󰀨 or disconnect electrical
supply to pump. Shut o󰀨 the gas supply at a
location external to the appliance.
Boiler Water
• Since the heat exchanger is made of cast iron,
the water chemistry must be checked. The system
pH must be in the range of 7.0 to 8.5. Chemical
treatment may be required.
• Before connecting the boiler, thoroughly ush the
system to remove sediment. Install a strainer or other
sediment removal equipment if necessary. The cast
iron heat exchanger can be damaged by build-up or
corrosion due to sediment.
• Do not use petroleum-based cleaning or sealing
compounds in the boiler system. Gaskets and seals
in the system may be damaged, which can result in
substantial property damage.
• Continual fresh makeup water will reduce
boiler life. Mineral buildup in the heat exchanger
reduces heat transfer, overheats the cast iron heat
exchanger, and causes failure. Addition of oxygen
carried in by makeup water can cause internal
corrosion. Leaks in the boiler or piping must be
repaired at once to prevent makeup water. Use this
boiler ONLY in a closed-loop system.
• Do not add cold water to a hot boiler. Thermal
shock can cause the heat exchanger to crack.
Commonwealth of Massachusetts
When the boiler is installed within the Commonwealth
of Massachusetts:
• This product must be installed by a licensed
plumber or gas tter.
• If antifreeze is used, a reduced pressure back-ow
preventer device shall be used.
See page 38 for sidewall vent air installations.
Freeze Protection Fluids
NEVER use automotive or standard glycol antifreeze.
Use antifreeze specically made for hydronic
systems; inhibited propylene glycol is recommended.
Thoroughly clean and ush any replacement boiler
system that has used glycol before installing the new
94 boiler.
Damage from Water Contact
DANGER
!
DO NOT attempt to operate any boiler if any
part of the boiler, burner, or controls has been
partially or fully sprayed with or submerged
under water. The boiler must either be replaced
or completely repaired and inspected. The boiler
and all components must be in good condition
and fully reliable before operation.
If these requirements are not met, operating
the boiler will cause re, explosion, and electrical
shock hazards, leading to serious injury, death,
or substantial property damage.
Saltwater damage: The immediate e󰀨ects of
saltwater damage are like those of freshwater,
with electrical components shorting out and the
removal of critical lubricants. However, salt and other
contaminants left behind can lead to long term issues
due to the conductive and corrosive nature of salt
residue. WM Technologies equipment contaminated
with saltwater or polluted water will no longer be
covered under warranty and should be replaced.
Electrical damage: If any electrical component or
wiring has, or is suspected to have come into contact
with water, replace the boiler.
Frozen Water Damage
Power outages, unattended residences or buildings,
boiler component failures, or other electrical system
failures in cold weather could result in frozen plumbing
and water damage in a matter of hours. Consult with
a boiler contractor or a home security agent to take
preventative actions, such as installing a security
system that operates during power outages, senses
low temperature, and initiates an e󰀨ective action.

7550-100-157/0523
94  4  
1
2
3
4
5
6
7
8
This section is intended to provide installation
instructions for qualied heating installers.
Section Contents
Prepare Boiler Location. . . . . . . . . . . . . . . . . 7
Prepare the Boiler . . . . . . . . . . . . . . . . . . 10
Boiler Assembly. . . . . . . . . . . . . . . . . . . . 12
Tankless Heaters . . . . . . . . . . . . . . . . . . . 28
Steam Boiler Controls . . . . . . . . . . . . . .29
Baffle Assembly and Installation . . . . . . . . .32
Commonwealth of Massachusetts Installations . .38
Venting and Combustion Air - General . . . . . . . . . . . .39
Venting and Combustion Air Options . . . . . . . . . 40
Room Air Openings . . . . . . . . . . . . . . . . . . 41
Breeching and Venting . . . . . . . . . . . . . . . . 43
Gas Venting Requirements — General. . . . . . . . 44
Oil Venting Requirements . . . . . . . . . . . . . . 46
Install Burner and Fill the System . . . . . . . . . . 49
Fuel Piping . . . . . . . . . . . . . . . . . . . . . . 50
Final Adjustments. . . . . . . . . . . . . . . . . . . 51

Installation Compliance Requirements
• Local, state, provincial, and national codes, laws,
regulations, and ordinances.
• National Fuel Gas Code – ANSI Z223.1/NFPA 54,
latest edition.
• Chimneys, Fireplaces, Vents, and Solid Fuel
Burning Appliances – ANSI/NFPA 211, latest
edition.
• Installation of Oil Burning Equipment – ANSI/NFPA
31, latest edition.
• National Electrical Code – ANSI/NFPA 70, latest
edition.
• Where required by the authority having
jurisdiction, the installation must conform to the
Standard for Controls and Safety Devices for
Automatically Fired Boilers – ANSI/ASME CSD-1,
latest edition.
IMPORTANT
The 94 Series 4 steam boiler met safe lighting and
other performance criteria when the boiler underwent
tests specied in UL 726 & UL 795, latest editions.
Checks Before Boiler Installation
1. Check for nearby connections to:
• System water piping
• Venting systems
• Fuel supply
• Electrical Power
• Combustion and ventilation air supply
2. Check area around boiler. Remove any
combustible materials, gasoline, and other
ammable liquids and vapors.
!
WARNING
Failure to keep boiler area clear and free of
combustible materials, gasoline, and other
ammable liquids and vapors can create an
explosion hazard, which can result in severe
personal injury, death, or substantial property
damage.
3. Check the boiler location to ensure it protects the
gas control system components from dripping
or spraying water and rain during operation or
service.
4. If a new boiler is replacing the existing boiler,
check for and correct system problems:
• System leaks causing oxygen corrosion or heat
exchanger cracks from hard water deposits.
• Incorrect expansion tank sizing.
• Lack of freeze protection in boiler water.



8550-100-157/0523
 94  4 
1
2
3
4
5
6
7
8
Flooring and Foundation
The 94 boiler is approved for installation on
combustible ooring, but must never be installed on
carpeting.
!
WARNING
Do not install the boiler on carpeting even if
a foundation is used. Installing a boiler on
carpeting can cause a re, which can result in
severe personal injury, death, or substantial
property damage.
1. The boiler mounting surface must be level and
suitable for the load.
2. Provide a solid foundation pad at least 4.0"
(101.6 mm) above the oor if any of the following
is true:
• Floor can become ooded.
• The oor is dirt, sand, gravel, or other loose
material.
• The boiler mounting area is severely uneven or
sloped.
3. Foundation may be brick or concrete
construction. The minimum foundation
dimensions are listed in Table 3.
4. If ooding is possible, elevate the boiler
su󰀩ciently to prevent water from reaching the
boiler.
Garage Installation
Take the following special precautions when installing
the boiler in a garage.
• Mount the boiler at a height above the oor as
specied in the latest edition of the National Fuel
Gas Code – ANSI Z223.1/NFPA 54, latest edition,
for U.S. installations.
• Locate or protect the boiler so it cannot be
damaged by a moving vehicle.
• Ensure that the installation complies with all
applicable codes.
Air Openings
Openings in oors, walls, ceilings, or roofs must be
designed for re stopping as required by local codes.
Vent pipe openings through combustible materials
must be 3/8" (9.5 mm) larger in diameter than the
vent pipe.
Air pipe openings should be 3/8" (9.5 mm) larger
in diameter than the pipe or as required by the pipe
manufacturer.
!
WARNING
Pipe openings that do not have the required
diameter can cause a re, which can result in
severe personal injury, death, or substantial
property damage.
Provide air openings for combustion air and
ventilation of the room. Follow the National Fuel Gas
Code – ANSI Z223.1/NFPA 54, latest edition for the
U.S.
Follow all applicable codes to size and verify
size of the combustion and ventilation air openings
into the space. See the Venting and Combustion
Air sections starting on page 39 for required air
openings and sizing.

Table 3 Minimum foundation dimensions
Boiler
Model
Length, L1
(inches)
Height, H
(All)
Boiler
Model
Length, L1
(inches)
1494 91
Consult burner
manufacturer
for required
clearances.
2094 127
1594 97 2194 133
1694 103 2294 139
1794 109 2394 145
1894 115 2494 151
1994 121 2594 157
Figure 1 Boiler foundation, when required
230032
H
H
66”
L1
L1
(2) ¼” x 3”
Steel plates x L1 long
x 51” apart
4”
51”
Back of boiler
Back of boiler
Always use steel strips as
shown for proper draw-up
and alignment of sections.

9550-100-157/0523
94  4  
1
2
3
4
5
6
7
8
Clearances
There are minimum clearance requirements for
the boiler from combustible surfaces. There are
recommended service access clearances. See
Figure 2 for all clearances.
IMPORTANT
Without the recommended minimum clearances for
service access, it may not be possible to service the
boiler without removing it from the space.
230033
Top
Top
Right
Side
Right
Side
Edge of opening within 12 inches of floor.
Edge of opening within 12 inches of floor.
Air openings
(when required)
Air openings
(when required)
Controls end
Front
Controls end
Front
Left
Side
Left
Side
Edge of opening within 12 inches of ceiling.
Edge of opening within 12 inches of ceiling.
Rear
Rear
Ensure that the installation complies with all state, local, and applicable codes.
Clearance from:
Minimum clearances to
combustible surfaces
(inches)
Minimum allowable
service clearances
(inches)
Recommended minimum service
access clearances
(inches)
Controls end (Front) 48 48 48
Right side 6 44 44
(clean and remove tankless heater)
Left side 6 6 6
Flue 9 9 9*
Rear 9 50 50 (breeching)*
Top 24 24 24
Floor 0 0 0
Single-wall vent pipe 18 18 18
Double-wall vent pipe Refer to vent pipe manufacturer's recommendations for vent pipe clearances.
Note: Allow su󰀩cient space for cleaning, servicing, and installing the burner. See burner literature for length and recommended
service clearances.
*Flue pipe and breeching clearances take precedence over jacket clearances.
Figure 2 Clearances for 88 Boilers

10 550-100-157/0523
 94  4 
1
2
3
4
5
6
7
8

Removing a Packaged Boiler from the Crate
Leave the boiler in the crate pallet until ready to place
in the nal location. Follow all removal instructions.
IMPORTANT
Cables used for lifting are not provided by Weil-McLain.
!
WARNING
Ensure the equipment and cables used for lifting
are designed to handle the load. See Table 4
for approximate weights of section assemblies.
Failure to comply can result in severe personal
injury, death or substantial property damage.
1. Move the crate to a solid, level surface. The crate
must be sitting securely on the ground.
2. Remove the top jacket panels and set aside until
after piping installation.
3. Remove four lag screws from the shipping brackets.
4. Remove the boiler from the skid with a crane or a
hoist. See Table 4 for lifting weight.
• Crane: Hook middle of each cable to the eye of
the crane.
• Hoist: Hook middle of each cable to the hoist.
Raise boiler o󰀨 skid. Use pipe rollers under skid
angles to roll the boiler.
5. Place 1/4" x 3" steel plates on the oor or
foundation. Space them 51" apart as shown in
Figure 1, page 8.
6. Place the boiler in the nal position. If using a
foundation, center the boiler on the foundation.
7. Level the boiler. Shim under legs if necessary.
8. Cut o󰀨 the cables.
!
WARNING
Cables are not intended for long-term use.
Cables may corrode inside the boiler, weakening
their lifting strength. Failure to remove cables
can result in severe personal injury, death, or
substantial property damage.
9. Inspect the block assembly for disjointed
sections.
10. Check the gas-tight seal of the ue collector hood
and clean out plates.
a. Check inside the section assembly for any light
passing through unsealed areas.
b. Mark all unsealed areas and check for the
following:
• Damaged gaskets.
• Displaced sealing rope.
• Loose bolts or nuts.
c. Correct all conditions and repeat the previous
steps. If unsealed areas still exist, contact Tech
Services before continuing with installation.
11. Proceed to page 16 and perform pressure
testing.
Boiler Model
Number
Approximate
Lifting Weight
(lbs.)
Minimum Sling
Length
(Crane Hook to
Boiler Lifting Lugs)
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"
Table 4 Section assembly lifting weights