Weil-McLain 78 Series Installation, Start-Up, Parts Download Page 1 | Manualshive

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Summary of Contents for 78 Series

Page 1: ...v v Installation Start up Boiler Parts PartNo 550 l4l 705 0493DCP v Boilerfor Gas Light Oil and Gas LightOil FiredBurners ...

Page 2: ...e of hazard which will or can cause minor personal injury or property damage if ignored Indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards When Calling or Writing about the Boiler please have model and series fiom boiler rating label ancl CP number s fronr boilcr jackct or controls Do not use petroleum based cleani...

Page 3: ...14 15 Section F Connect Steam Piping 16 19 Section G Install Jacket 2O Section H Pipe Tankless Heaters 2O Section I Install Water Boiler Controls 21 Section J Install Steam Boiler Controls 22 23 Section K Connect Breechinfl and Venting Systems 24 SectionL Install Burner 25 Sectiot tM Wiring and F uelPiping 25 SectionN Make Final Adiustnlents 26 27 Section O Data and Dimensions 28 29 Section P Part...

Page 4: ... ceiling one v ithin l2 inches of floor Minimum dimension of each opening 3 inches When all air is taken from rvithin building each opening should be at least one square inch 1 ooo Btuh boiler input and freell connect with areas having adequate infiitration from outside When all air is taken from outdoors each opening should connect directly or by ducts with outdoors or crawl or attic spaces that ...

Page 5: ...ches clouble vall vent pipe rel erto vent pipe t llatlul rctltr cr s re ontlllendatiot ts lbr vent pipe cle rrances Lay a foundation if needed Floor constmction and condition must be suitable for weight of boiler when filled with water Seeback cover page for boiler water weight A level concreteor brick foundation is required when o Floor couid possibly becomeflooded o Non levelconclitionsexist 2 M...

Page 6: ...boiler 3 Place boiler in final position Center boiler on founda tion if used 4 Level boiler Shim under skid angles il necessary 5 Cut off cables Cables rre not intended for lon term usage Cables nrat c orrode inside boil cr veakeninq their lifting strength Failure 1o renlove t erblescan result in severe personal injtln de rth or sub sta n li irl l ro l e n vd rtttta te Inspecl block assembly lbr c...

Page 7: ...ces S E A L I N G PlaceI 2 sealingrope in groove Around curves grasp a1 l intenals and push together Do not stretch E i l ffi 1fi r 9 1l sibility of flue gas leakage and carbon rnonoxide emissions causing severe personal injury or death Remove anv grit liorn pofl mzrchined surlaces with clean rag Itr 3 J iJ fi 1 ili n tem Severe darnage Losystem compo nents can result causing substzrnlial propcrly...

Page 8: ...her and nut on end to bc tightencd Use nut only on other end b Unilbrrnlv clra vscctions together starting atwash erlnut end c Draw rods shoulcl bc torqtrccl to a range of 9O to lOO ft lbs Do not back ofTclr ru rocls Metal to nrctal t ontact u ill bc acl rievecl around porl openings See Fier rre6 Il Qap does exisl it should be no gre rtcr th rrr 032 Check wit h feeler gauge If for any re lson g tp...

Page 9: ...mblies on front and back sections l Instirll lj orrtolrscn ation port assernbly l r pph 1 8 t ontinrrous be rd ol sc rlir rg ropc adhe sivt in groo orr obst r r ntionport lr osiliorr l Fi st irlirrrlropc irr lroot s Overlap ends at l ils1ortt ittt lr S ccl rn a sst rrrb l v to se tio l i U st 5 l6 18 x 3 4 slot te l l tt itclscreu s 2 Repeat abovc stcps lirr back obscn rtiort porl lrssernbly lf us...

Page 10: ...y gasket on flue collar flange making strre to line up bolt holes on gasket ancl flangc 2 Mount collar on back section a Remove any grit lrom threads inside tapped holes wilh clean raq Install one 5 16 x l flanged bolt hallkay into bottonr hole in section Rest llue collar on lizrnged bolt making sure to not damage gaskct Install 5 I6 x l ll rnQeclbolts in lo ver two side holes Tightcn all 3 bolts ...

Page 11: ...ing rope to hood assembly See Figure 9 a l ay hood on floor rvith flanged side up b Wipe flanged surl ace rvith clean rag to remove dirt and oil c Apply double faced tape to llangecl surface d Apply rope to tapc beqinning on one side of open end of hood leaving 4 extending past edge Around corrlers bend rope do not cut Do not stretch roPe Do not pre cut rope Gas tight seal must be maintained to Pr...

Page 12: ...rt hood d Tighten six 5 16 x I flanged bolts and flanged nuts on flue collar to 30 35 in lbs Overtightening bolts in flue col lector hood assembly will cause gasket material to extrude caus ing possible flue gas leakage and carbon monoxideemissions resulting in severepersonal iniurv or death Check gas tight seal of llue collector hood and flue collar Gas light seal must be maintained to prer ent p...

Page 13: ...t 3 Drain boiler and remove air vent boiler dr rin gauge t Ot Ut liom tappings used for controls and accesso oPTtoNAL t t 2 TAPPING OPTIONAL INSPECTION TAPPINGS CONTROL TAPPING TABLF LOCATION stzE STEAM ATER A Skim Tapping Primary Probe type Low ater Cutoff or Additional High Limit Control B 3 Steam Relief Valve Water Relief Valve c l I Combination High Low Limit Control c r c 2 Primary Water Leve...

Page 14: ... BOILER MODEL SUPPLY PIPESIZE A RETURN PIPESIZE B 378 2 2 478 2 12 2 1t2 578 678 I 3 778 t278 4 All piping sizcsb rsetlort 20 F temper tlurerise throrrghboiler F rtrknown flow rates or higher flow rate thror rgl rboiler size piping per thble below F lorvat higher velocities than shorvn in Table below lbr pipe sizc r ur clzrmageboiler caus inq srrbstirnli rl properrly rlirrrrlqt R E C O M M E N O E...

Page 15: ...13 Calcul rte only secondary piping circuit resistance Boiler resistance will be about equal to three 90 degree elborvs ol secondary pipe size Operate each boiler and its secondary pump from EMCS system Do not maintain boiler at predeter nrined uv rter temperature Prirnarl punrp GPM and head calculation should not include secondary boiler circuits Primary pump can operate continuously during heati...

Page 16: ...onclensate return same as equal izer J pipc size lt Ir rst rllsvstenr dr rir r rlvein lowest part of rclurn piping close to boilcr ASME size requiremenls are shown in Table pagcr I4 Conncct colcl water lill piping ersshown in Figure 14 Also shown are recomnlcnded valves and water metcr il usecl Water nreter will ck lecl aclded make trp water ir rdit atir rg leaks in systenr COLD WATER F L L TO CON...

Page 17: ...ine to bottom of header 378 through 578 Steam Boiler PiPing Figure 15 RISER srzE c 24 minimum from water line to bottom of header 678through 978 Steam Boiler PiPing Figure l6 SYSTE14 SUPPLY FULL SIZE OR REDUCING ELBOW EQUALIZER PIPE SIZE J 4 t l t N TO TOP O F PIPE BACK O F BOILER t CLOSE NIPPLE GRAVITY CONDENSATE RETURN closE NIPPLE GRAVITY CONDENSATE RETURN 24 minimum from water line to bottom o...

Page 18: ... vALVE STRAINER FEED PUI 1P CHECKVATVE o Condensate Piping to Boiler Figure 18 ATMOSPHERE CONDENSATE RECEIVERCAPACITY TABLE BOILER M O D E L l B R GROSS OUTPUT LBS STEAM PERHOUR GALLONS CONDENSATE PERHOUR MINIMUM CONDENSATE RECEIVERCAPACITY GAL RECOMMENDED CONDENSATE FEED P U M P CAPACITY GPM A T I 5 P S I t 5 M t N BOILER OPERATION 3 0 M t N BOILER OPERATION 4 5 M l N BOILER OPERATION 6 0 M t N B...

Page 19: ...kinr tapping soc pitgc 22 Clortrtectfr r1lsttr condensate rcceivcr D tnstall stop valves per ASME code requirements _ and slow opening automatic steam valves when used Use EMCS system to open automatic steam valve befbre firing burner E Construct common supply drop headerwith pipe size at learst samesizeas largestboiler headersize Use EMCS system with header mounted pressure control s to sequcnceb...

Page 20: ...able below Follow nranulhcturer s instructions to install TANKLESS HEATER RATINGS TABLE TANKLESS HEATER MODEL CONTINUOUS DRAW GPM INLET AND OUTLET TAPPINGS 78 24 6 5 3t4 GPM hcatccl frorn 4O F to lzlOoF lOOoli lcmperature rise with 2OO0Fboiler water tentperature Continuous clraw no recovelv oeriod Operating control with small ad iustable dilferential scale is recommended Install in tempererturc co...

Page 21: ...ge to boiler building and personnel and is not coveredby boiler warranty Relief valve must be installed with spindle in vertical position Use fittings provided with boiler Do not make any other connection in that piping Relief valve discharge line must be pipecl near floor close to drain to elim inate potential of severe burns Do not pipe to any area where freezing could occur Do not plug valve or...

Page 22: ...to any area where lreezing cotrlcl oc crrr o not phrg v ilr t or placc ilnv obsttuction in clischarge line Install water level controls ancl gauge gl rss rs shown in Figure 24 l Irittings for controls to berft rrnishcd by others trlEil li l ill ill l i l 1 l ttinqs rrrs utr r hLrlclorirrs r ill occur el control is not shorr nin Figure 24 orr bociv rnark on control and n L irtrrll rt tu rt r s i n ...

Page 23: ...n boiler and make up nater f eeder on tank Use separate low water cut oll on boiler r henback up is needed Do not install combination low water cut off and feeder as back up control on boiler Feecler will operate before pump control operates WATER LEVEL CONTROL LOCATION TABLE PRIMARY WATER LEVEL CONTROL CASTING LINE H E I G H T ABOVE BOTTOM OF GAUGE GLASS A BACK UP ATER LEVEL CONTROL CASTING L I N...

Page 24: ...positive pressure at lrre collirr Minimtrm r himney height al ove roof is 3 fcct St r F igrrrcs27 and28 Stub Vent Forced Draft Single Boiler Figure 25 Stub Vent Forced Draft Multiple Boiler Figure 26 Construct metal breeching o See back cover for minimum breechinq cliatttctcr Select material type and thickness in conrplialrce ilir local codes E J i 1 ffi l ff 11 carbon monoxide emissions through s...

Page 25: ...cal Code ANSI NFPA 70 o Any additional national state or local codes 2 Follow burner manual and wiring diagram ibund in burner inlbnnation packet 3 Use 14 ga wire lbr oper rting and safety circuit wiring 4 Where burner motorvoltage clilfers from control voltage supply proper voltage to each Size fuscd disconnectfs and conductors per National Elcctric rl Code ANSI NFPA 70 To install gas and or oil ...

Page 26: ...rr lrrrtrrt r rrrr rq conrbustron test equipment to assrlre proper operation Do not lire boiler itl rotrt water Sections will overheat damaging boiler and resulting in severe property danrage l lock open breeching damper 2 Refer to bumer manual for start up and service 3 Irt bumer advance to high fire Heat boiler to design conditions 4 Using combustion test equipment ad jusl burner or r l2o o 4o1o...

Page 27: ...skim piping Re insert plug at boilcr skinr tap circulat or and expansion t rnk prng B Closedrain cock Fill with liesh water to norrnal water 5 Follow zrntilieeze manulh trrrt r s instntctions Iine Start burner rnd stearnfor I5 n rir nrles to remove Check boiler for gas tight seal Skim steam boilers Clear r nl1neulr ir rst rll steanrboilersto only remo c oil Failtrre to properlv clean can resr rlti...

Page 28: ... tt2 27 U2 34 3 8 35 t 12 578 2 4 2 4 2 3 2 3 34 tt8 8 42 tt2 4 t12 4 3 8 42 u2 778 2 4 2 4 2 3 2 3 4 t tt 8 l 0 4t t 12 4t u2 48 3 8 49 tt2 878 2 4 2 4 2 t 2 3 48 8 t 0 4 t U 2 48 tt2 55 3 8 s5 tt2 978 2 4 2 4 2 3 2 3 55 8 t 0 4 t U 2 55 2 62 y8 53 tt2 078 2 4 3 4 2 3 2 3 62 tt8 27 18 t 0 4 l l t 2 A A U2 69 3 8 70 tt2 I t 7 8 2 4 3 4 2 3 2 3 69 8 34 tt8 t 0 4 l 2 69 t2 76 3t8 7 7 U2 1278 2 4 3 4...

Page 29: ...SectionO Data and Dimensions coNT D r_ 101 4 Gr l_4 a_4 1tz Err l l lI D1 F 1 tr 2 c D I Nn RETURN f Back E L Side Intermediate 29 ...

Page 30: ...Section P Parts I I qk 9 t v G 1 M Y 1 l 4 I r 1 N rr l ffi 30 d ...

Page 31: ...FLUECOLLECTORHOOD D I t B 3 4 l FLUE COLLECTOR HOOD E I t B 3 5 t FLUECOLLECTORHOOD HARDWARE KIT includes flat stitched sealing rope double faced tape fluecollargasket collectorhoodgaskets holddownclips hardware 8342 K COLLECTORHOOD GASKETKIT lncludes fluecollectorhood gasket fluecollargasket flat stitched sealing rope anddouble faced tape i l 8 3 r l L FLUECOLLECTOR HOOD END CAP 8343 M FLUECOLLAR...

Page 32: ...signator for factory assembled 78 ABL 478 Substitute P for 8 for fire testedpackage unit PL 478 r Substitute S for steam W for water O For T lntermediate section s andtankless heater s addsuffix numberrequired TlH for T lntermediate section s with cover plate s only addsuffix numberrequired TlP a Burner input basedon maximumof 2 000feet altitude for higheraltitudesconsultWeil Mclain represencative...

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