No.76 BOILER - Oil Tech Talk
Contents
1. Temperature Rise Temperature Rise 4 5 GPM 4 0 GPM inlet and Outlet Tappings ya Heater Number 35 S 29 STORAGE HEATERS 212 180 Heater Capacity Gallons 40 140 Rise 140 in 3 Hrs 200 500 Gallons Heater Capacity Gallons 40 140 Rise 205 in 3 Hrs 250 500 Gallons 18 Heater Number 816 Recommended Storage Tank Weil McLain Ratings Gallons of Water per min heated from 40 to 140 with 200 F boiler water temp Continuous Draw no recovery period inlet and Outlet Tappings STORAGE HEATER HOOK UP Where the boiler was ordered with storage heater s for best operation the domestic water storage tank should be located as high as possible above the storage heater s A vertical do mestic water storage tank may be used if the bottom of the storage tank is located above the boiler To maintain optimum gravity hot water circulation the horizontal flow piping from the storage heater s to the tank must pitch upward at least 1 inch for each 10 feet of piping and the horizontal return piping from the storage tank to the heater s must pitch downward at least 1 inch for each 10 feet of piping Use as few pipe fittings as possible so that the least possible resistance will be encoun tered The STORAGE HEATER RATING table gives the stor age heater capacities and the recommended storage tank size INSTALL BOILER CONTROLS Steam Boiler A low water cutoff safety valve pressure2. Erecting Instructions No 76 BOILER Weil McLain GENERAL INSTRUCTIONS If the boiler was ordered as a complete package thoroughly check the boiler for any concealed damage If the boiler was ordered as factory assembled or field assembled open all boxes and check the contents against the packing lists In the event of shortage or damage notify the transportation company im mediately Boiler must be installed in accordance with these in structions so as not to void our warranty Boiler must also be installed in accordance with Section IV of the ASME Boiler and Pressure Vessel Code and any applica ble governmental and insurance codes AIR SUPPLY FOR BOILER ROOM Provisions must be made to supply sufficient air to the boiler room at all times for combustion ventilation operation of the barometric draft regulator where used and prevention of less than atmospheric air pressure in the boiler room An opening to the outside with a free cross sectional area of at least 1 square inch per 7 000 BTUH burner firing rate is rec ommended CSA requires 1 sq in per 5000 BTUH input For each 1 000 feet above sea level increase the fresh air opening by 4 percent The boiler room should be isolated from any area served by exhaust fans DO NOT INSTALL AN EXHAUST FAN IN THE BOILER ROOM CHIMNEY OR VENT also refer to BREECHING ERECTION The No 76 Boiler is designed for pressurized forced draft fir ing The No 76 Boiler for ligh
3. Engineering Department Based on average water temperature of 170 F in radiators Stack gas volume at outlet temperature For light oil natural draft Draft overfire must be added to obtain draft required at flue collar For light oil gas and gas light oil forced draft Add 0 10 W C for overfire pressure ip When chimney is fined with the largest standard clay chimney tile the equivalent area is considered the same as the unlined chimney area x For forced draft firing maximum positive pressure cannot exceed 100 W C at the flue collar INEPT EAT SUPPLY L Y Gort 4 3i em C 4 T a 7 l i W BOILER SECTIONAL LENGTH T E SIDE WATER LINE INTERMEDIATE Dimensions Inches E WEIL Me LAIN Michigan City Indiana 46360 A Marley Company
4. add suffix number required TIP A Burner input based on maximum of 2 000 ft altitude for other altitudes consult Weil McLain Application Engineering Department No 2 fuel oil Commercial Standard Spec CS75 56 Heat value of oil 140 000 BTU G BGL Units are built to operate with gases of 1 000 BTU 0 60 specific gravity Minimum gas pressure required 7 0 inches W C For other pressures and or gases consult Applica tion Engineering Department NOTE SEE CONTROL TAPPINGS TABLE AND FIGURE 5 FOR TAPPING p INFORMATION H BACK 26 IN MINIMUM IF STORAGE HEATER IS USED 3 NPT RETURN ua Li AIN FRONT PLATE Boiler Iin Canada Wylain Canada LTD LTEE 126 East Dr Brampton Ontario LET 1C2 No 76 BOILER Supply Tappings Return Tappings Number Number amp Size Number amp Size Weil McLain Draft B R Chimney Net Firebox Loss thru a Natural Draft Forced Draft wx Volume Min Vent Cu Ft Dia Inches t At combustion condition of 1214 t4 CO2 t Net i B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pick up Water ratings are based on a piping and pick up allowance of 1 15 steam ratings on an allowance of 1 333 An additional allowance should be made for gravity hot water systems or for unusual piping and pick up loads Consult Application
5. hood collar after adjusting the breeching damper Where excess negative draft conditions prevail in the breeching between the chimney or vent and the breeching damper adjust the barometric draft control to provide approx imately zero to 0 05 inches water column pressure between the breeching damper and the barometric control BURNER AND BAROMETRIC 07 11110 am DAMPER ADJUSTMENT FOR NATURAL DRAFT FIRING Start the burner and adjust the air band so that a clean yel low oil burner flame with slightly smoky tips or a clean gas flame is established Use combustion test instruments for final adjustment of the burner flame with the burner on high fire and the system wa ter temperature raised to approximately the design condi tions A smoke reading of a trace to No 1 on the Shell Bacharach scale is recommended with 111 2 to 12 2 percent CO for No 2 fuel oil A CO reading of 9 to 10 percent is recom mended for natural gas A test should be taken to assure that CO does not exceed 04 percent in the flue gases for gas firing When the burner is on and adjusted to the above combustion conditions adjust the barometric draft control to provide 0 02 inches of negative draft overfire NEW STEAM BOILER New steam boilers must be cleaned properly previous to or during the first few days of operation Follow the cleaning rec ommendations listed in the START UP SERVICE AND MAINTENANCE INSTRUCTIONS Do not use chemical cleaners or PETRO
6. plugs and other accessories listed to this point in the instructions are mounted on the boiler Follow the Jacket Erecting Instructions packed in the jacket carton for jacket installation procedures TANKLESS HEATER HOOK UP Where the boiler was ordered with tankless heater s it is recommended that the piping to and from the heater be sized no smaller than the heater inlet and outlet piping connections The tankless heater piping should be installed as illustrated in FIGURE 10 Where the boiler was ordered with multiple tankless heaters a cold water supply header with individual risers to each heater must be employed and the hot water out Page 7 Erecting Instructions No 76 BOILER Weil McLain lets from each header must be headered It is recommended that a flow regulating valve be installed in the cold water sup ply piping to each heater Each flow regulating valve should be sized according to the intermittent draw rating of each tankless heater Do not pipe multiple indirect water heaters in series An automatic mixing valve may be installed in the do mestic hot water supply piping from the heater s to regulate the domestic hot water temperature Install the operating con trol in the control tapping in the heater plate In hard water areas it is advisable to soften the cold water to the heater s DOMESTIC WATER HEATER CAPACITIES TANKLESS HEATERS Intermittent Draw GPM Continuous Draw GPM 100 Average 100
7. pressure regulator are furnished as standard equipment For propane gas a lock up gas pressure regulator furnished by the gas sup plier must be installed at the storage tank and should provide lock up pressures not exceeding 14 inches water column The gas piping must be sized to provide the minimum re quired inlet gas pressure at the manual main shut off gas valve when the burner is operating at the rated input Consult the local utility regarding gas pressure piping pressure drops and any local gas piping requirements The gas piping should be installed in accordance with the specifications of the National Board of Fire Underwriters or Natural Fuel Gas Code and any additional code requirements which may apply A drip leg should be installed at the inlet of the gas connection to the burner Where the local utility re quires that the drip leg be extended all the way to the floor place an appropriate length of pipe between the cap and tee All gas piping should be tested for leaks after installation with air pressure or inert gas of at least three times the gas pres sure that will be used Fuel Oil Piping The rules of the National Board of Fire Underwriters and any local or national code requirements which may apply should be followed in locating and installing the fuel oil tank and the fuel oil piping A two pipe fuel oil piping system is rec ommended when the bottom of the tank is below the burner WARNING g If any part of the f
8. shut off oil valve should be provided in the suction line near the burner and either at the tank or near where the suction line enters the building from an outside tank If man ual shut off oil valves are located in the return piping a by pass relief to the tank with an oil pressure relief valve must be provided The return line piping should be run to within 4 to 6 inches from the bottom of the tank Suction line piping should be pitched slightly toward the fuel storage tank whenever possible Particular care should be exercised not to create an air trap in the suction line There is always a slight amount of air in suspension in fuel oil and if traps are present they will gradually fill with air and the fuel unit will lose its prime It is good practice to provide a tee and plug at the highest point in the suction line to aid in priming the fuel unit BOILER MUST BE SEALED GAS TIGHT For proper combustion efficiency and safety to the building occupants be sure the boiler is sealed gas tight For forced draft firing in order to test the boiler seal remove jacket side and top panels Shut off the breeching damper and start the burner keeping it on prepurge Observe all sealing points and mark any that are not gas tight Turn off the burner and open the breeching damper Seal any areas that are not gas tight by covering the outer surface of the sealing rope with silicone sealant Replace the jacket panels For natural draft firing in
9. support the weight of the boiler Locate the boiler foundation to pro vide proper clearances for installation of the piping burner and internal water heater s Allow a minimum clearance of 22 from the back of the boiler for breeching erection Allow 18 clearance to the left side for cleaning and for tankless heaters Allow 26 clearance to the left side if storage heaters are used A level concrete pad or curb foundation is suggested of the size shown in the table and FIGURE 1 The height of the boiler foundation should be at least 2 If the boiler is to be installed directly over electrical wiring or telephone cables in conduit buried in the concrete floor of the boiler room a 1 thick insulated mat covered with foil should be laid on the floor underneath the boiler sections foil face up BOILER FOUNDATION SIZES BOILER NO 476 576 676 FIGURE 1 ASSEMBLED SECTIONS If the boiler was ordered completely packaged or with the sections factory assembled locate the unit on the boiler foun dation or on the boiler room floor After the boiler has been po sitioned proceed to HYDROSTATIC PRESSURE TEST OF BOILER Part No 550 110 185 0383 WP Erecting FARS A No 76 BOILER Weil McLain SECTION ARRANGEMENT TABLE WITH INDIRECT WATER HEATERS BOILER NO OF HEATERS ALL HEATERS MUST BE ON LEFT SIDE OF BOILER F THI B F THLTLB F TIH TIH B F THI I TI 8 F TI Ti t 1 T1 B F Front Section B Back
10. the rope overlap at least 1 Position the draft hood collar to fit over the flueway outlet on the back section Secure the draft hood collar to the back section using the 3 8 x 1 hex head cap screws and washers provided see FIGURE 6 HYDROSTATIC PRESSURE TEST OF BOILER 1 If the boiler was ordered with optional 11 2 cleanout and inspection openings on the sections plug these tappings using the 1 2 brass plugs provided 2 Install a drain cock not supplied in the 3 4 drain tap ping size to ASME Code requirements Refer to the CONTROL TAPPING TABLE and FIGURE 5 3 Install a water pressure gauge in one of the boiler tap pings so the boiler water test pressure can be measured 4 Install a bleed valve in boiler tapping K to vent air as the boiler is filled with water 5 Plug all remaining boiler tappings including the re turns Refer to the CONTROL TAPPING TABLE and FIGURE 5 6 Fillthe boiler with water and completely vent all air Test the boiler with water pressure not exceeding 45 pounds per square inch or 11 2 times the boiler working pressure whichever is greater F Can NSS t _ WATER LINE E gt A i WARNING 4 Submit the boiler to this test for at least s i 10 minutes but for no longer than 30 minutes RETURN lt Te T a Ag y 4P IN FRONT i ng AS ened R PLATE cS 2 7 Thoroughly inspect the entire boiler for water leaks At eh a ee the end of the test period lo
11. APPINGS table and FIGURE 5 5 Install any additional limit controls in the proper tap pings as indicated in the CONTROL TAPPING table and FIGURE 5 6 Install any additional or optional water boiler controls ac cording to the control manufacturer s instructions A combination low limit operating control and high limit control is furnished as standard equipment The low limit op erating control should be set according to the design require ments of the heating system The high limit control should al ways be set at least 20 F higher than the low limit control setting where possible 250 F maximum allowable boiler wa ter temperature For additional information on the controls refer to the control manufacturer s instructions No 76 BOILER Page 9 Weil McLain S3e7 FIGURE 13 BREECHING ERECTION FOR FORCED DRAFT FIRING also refer to CHIMNEY The No 76 boiler for forced draft firing differs from the No 76 boiler for natural draft only by the addition of a manually adjusted flue collar adapter with built in breeching damper see Figure 13 Long horizontal breechings excessive num bers of elbows or tees or other obstructions which restrict the flow of combustion gases should be avoided The breeching damper damper locking plate and breeching damper handle are furnished as an assembly Slide the damper assembly over the smoke collar making sure it is firmly set in place Drill three holes an
12. LEUM based products in this boiler ADDITIONAL INSTRUCTIONS Before leaving the job make sure the unit checks elec trically and the proper main burner flame is established Be sure the thermostat heat anticipator is at the proper setting and the room thermostat or operating control is adjusted to provide the desired room temperature BOILER SERVICE AND MAINTENANCE The boiler START UP SERVICE AND MAINTE NANCE OPERATING INSTRUCTIONS contain infor mation for the owner Review this information with the owner and or the owner s representative and be sure they receive all instructions Erecting Instructions Gross B R Output BTU HR t 264 000 323 000 336 000 408 000 480 000 552 000 624 000 Steam Water BTU Hr BTU Hr 198 000 242 300 252 100 306 100 360 100 414 100 468 100 4 Substitute BL for light oil BGL for gas light oil BG for gas or H for boiler only for use with approved light oi burners Add prefix A to designator for Factory Assembled No 76 example ABL NOTE For gas and gas oil burners only 476 and 576R boilers can be furnished only with Peabody Gordon Piatt burners 576 boilers can be furnished only with Power Flame burners 576R boilers not available for light oil Substitute S for steam W for water For T Intermediate section s and tankless heater s add suffix number required TIH for T Intermediate section s with cover plate s only
13. Make sure burner plate is in stalled with the round secondary air opening to the left see FIGURE 6 Make a small continuous bead of sealing rope adhesive in the bottom of the sealing groove located around the flange of the front observation port assembly Position the 3 3 diameter by 12 long sealing rope in the sealing groove making sure the ends overlap at least 1 Install the front observation port assembly using the number 10 32 x 3 4 truss head screws provided see FIGURE 6 If the boiler was ordered with TI intermediate sec tion s install the indirect water heater s and gasket s or heater opening cover plate s and gasket s using the 3 8 x 3 hex head screws and washers provided see FIGURE 6 Erecting Instructions No 76 BOILER Weil McLain 13 14 16 Place a 1 4 x 11 2 carriage bolt in the cleanout opening as shown in FIGURE 6 Place a washer and nut over the bolt to hold it in place Place the 10 2 x 17 3 cerafelt blanket insulation pieces against the cleanout plates Mount the cleanout plate over the opening and bolt the cleanout plate in position see FIGURE 6 Repeat Step No 13 for the remaining cleanout plates Make a small continuous bead of sealing rope adhesive in the bottom of the sealing groove around the perimeter of the draft hood collar Position the 3 8 diameter by 42 long sealing rope in the groove on the draft hood collar making sure the ends of
14. ONTROL TAPPING table and FIGURE 5 WARNING To avoid water damage or scalding the safety valve outlet must be piped to a floor drain or near to the floor Do not pipe the safety valve discharge to any area where freezing temperatures could occur 2 Install the low water cutoff see FIGURE 11 in accor dance with the CONTROL TAPPINGS Table and FIG URE 5 Where an optiona low water cut off combination low water cut off and feeder or combination low water cut off and pump contro is employed install the control in accordance with the CONTROL TAPPING table and FIG URE 5 using fittings not furnished If a low water cut off is to be used that is not dimensionally diagrammed in FIGURE 11 locate the cast on body mark of the control 2 below the normal water line Do not use a water level con trol with quick hook up fittings on any No 76 steam boiler PRESSURE e RR 2 READ 4 ELBOW 2 REQ D 15x 4 BUSHING FIGURE 12 20 SYPHON Tia w Erecting Instructions 3 Install the gauge glass cocks water gauge glass and gauge glass guards in accordance with the CONTROL TAPPING table and FIGURE 5 4 Install the steam pressure operating and high limit con trols and the pressure gauge in the proper tapping as indi cated in the CONTROL TAPPING table and FIGURE 5 Use the pigtail syphon and fittings furnished see FIG URE 12 5 Install any additional or optional steam boiler controls ac cording to the control manufac
15. Section Intermediate Section TI Intermediate Section with Tankless Heater Opening A Tl section can be located in this position instead of regular intermediate section but installer must cut jacket side panel to accommodate heater opening no knockout is provided SEALING ROPE Listed in the SEALING ROPE USAGE TABLE are the places sealing rope must be used and the diameter and length of each piece For expediency the sealing rope can be pre cut prior to starting the section assembly SEALING ROPE USAGE TABLE NOMINAL DIAMETER OF CUT LENGTHS SEALING ROPE ROPE USAGE AND LOCATION 98 Perimeter of each Section 42 Drafthood Collar Burner Mounting Plate Observation Port Frame V2 fa 12 SECTION ASSEMBLY 1 Prepare the back section for erecting the boiler a Lay back section on floor with ports facing up Apply water glass as an adhesive to the target wall area i e back end of firebox of the section Press flexible refractory blanket into position see Figure 6 Locate the back section on the boiler foundation shown in FIGURE 1 Screw a piece of 3 diameter pipe at least 22 long into the 3 return tapping in the back section Block under the 3 pipe to hold the back section up right without additional support These sections are top heavy and will not stand individually without sup port Make sure that the section remains plumb The 3 diameter piece of pipe can be removed after several sec
16. d secure using three 10 bolts and nuts see FIGURE 13 Complete the installation of the breeching from the damper to the chimney or vent using the following procedure 1 Fit a piece of full size heavy gauge steel breeching same diameter as draft hood collar over the damper The force fit of the breeching onto the damper must be gas tight and should be held together with several bolts or screws 2 Refer to the last page of these instructions under No 76 RATINGS and determine the minimum recommended breeching diameter for the size boiler being installed Use heavy gauge steel breeching which can be welded to con nect from the chimney or vent to the piece of full sized breech ing on the damper assembly Re breeching must be gas tight using welded seams and joints Where the breeching diameter will be smaller than the diameter of the damper assembly a ta pered type reducing fitting which provides less resistance to flow of combustion gases is recommended BAROMETRIC FORCED DRAFT In the event the boiler is connected to a high chimney which provides too much natural draft install the barometric draft control furnished with the boiler in the breeching as close to the chimney as possible a Erecting Instructions No 76 BOILER Weil McLain ee a ee SS SS SS BREECHING ERECTION FOR NATURAL DRAFT FIRING also refer to CHIMNEY The No 76 boiler for natural draft differs from the No 76 boiler for forced draft fi
17. ection Regular Intermediate Section Tankless Intermediate Section Back Section Burner Mounting Plate Cerafelt Blanket Insulation 101 2 x 17 8 Tankless Heater 8 Tankless Heater or Heater Cover Plate Gasket Heater Cover Plate Cap Screw 3 8 x 3 4 Draw Rod 5 e x 9 Draft Hood Collar Cap Screw 3 e x 1 Washer 3 8 Cleanout Plate Carriage Bolt 4 x 13 4 Washer t a Hex Nut 1 4 FIGURE 6 33 l eck 33S Observation Port Screw 10 32 x 3 4 Observation Port Assembly Sealing Rope 3 8 Stud Tap End 1 2 x 41 4 Hex Nut 1 2 Retainer Front Refractory Washer 1 2 Wing Nut 1 4 Secondary Air Shutter Machine Screw 1 4 x 11 2 Sealing Rope 1 2 Front Plate Refractory Clear Sight Glass 2 Dia x 1 8 71 2 Square Cut Seal 31 2 Square Cut Seal Washer 5 8 Hex Nut 5 8 Insulated Combustion Chamber Back Piece For BG and BGL 76 boilers refractory is cast into burner mounting plate Page 5 Erecting ag Instructions No 76 BOILER Weil McLain mended piping connections and minimum recommended pipe RECOMMENDED PIPING CONNECTIONS sizes for No 76 water boilers Reverse water flow through w FOR WATER BOILERS the No 76 water boiler is not recommended In most cases it is advisable to pump water away from the boiler by connect SYSTEM FRONT ONLY ing the supply piping t
18. for clean ing and heater installation Discard the s diameter rods which are required only during shipment These rods must not be used to draw the sections together CLEAN OUT is OPENING 72 FLEXIBLE ae ELASTOMER SEALING a RING SEALING ROPE 31 2 FLEXIBLE ELASTOMER SEALING RING FIGURE 2 Page 2 Erecting Instructions No 76 BOILER Weil McLain 1 8 BEAD SILICONE SEALANT ELASTOMER SEALING RING FIGURE 3 a Position the intermediate section so that the aligning lugs will fit into the sockets of the section see FIGURE 4 Oil the threads of four 4 of the draw rods s x 9 and slip them through the lugs on the top and sides of each section Place a washer only one washer per draw rod under each nut to be tightened Put a drop of oil between washer and nut Starting with the draw rods nearest the port openings draw the sections together uniformly until the metal around the ports touch and the pads at the opposite cor ners touch When properly pulled together the gap around the port openings should be less than 0 032 Check with a feeler gauge c Do not continue to draw sections together after metal to metal contact has occurred Do not back off the draw rod nuts 8 Set the remaining boiler sections into position with the TI sections placed if used in the proper order given in the SECTION ARRANGEMENT table Check the sealing rope seal of each section before
19. gauge gauge glass and cocks blow down valve and operating and limit pressure controls must be installed on this boiler to meet ASME code requirements LOCATION LOCATION a E NO NO 2 i ah ERE A s Bs i 3I BOILER ey AN WATER LINE me Gas 5 LOW WATER D J CUT OFF H r FIGURE 11 Page 8 Recommended Locations For Low Water Cutoff Water Feeders and Pump Controllers When Used on Weil McLain Steam Boilers LOCATION NO 1 LOCATION NO 2 Primary Casting Line Casting Line Water Location Below First Back up Location Below Level Water Line Water Water Line Controle Dim A Controle Dim A 150 a es ee 61 63 4 aera ee eee 93 amp 94 2 Zae ee 51 2 amp 51 S 2 3 247 2 3 61 amp 63 61863 93t amp 94t 61 amp 63 4 938948 247 2 93 amp 94 8 51 2 amp 51 S 2 1508 1500 e Other manutacture s controls providing similar function may be used provided they are properly locatec arc ave selected to handle the boiler evaporative capacity Control locations as z catea above refer to the control body mark or line on the con trol body casting t Use low water cutof t act on only pump controller function should only be used on Dack up controller to provide low water cut off func function 1 Install the steam safety valve in the proper tapping as in dicated inthe C
20. ise through boiler is permissible when boiler piping connections are sized using above Table 1 INTERMITTENT flow at HIGH velocities may damage any boiler 31 WAT 6 a TABLE II tine Te a FOR UNKNOWN FLOW RATES y NIPPLE Pa FIGURE 8 SUPPLY RETURN O al BOILER PIPE SIZE PIPE SIZE Be NUMBER B j Ne 476 and 576 2 gf y STEAM BOILER PIPING 7 x CONDE NSATE 476 AND 576 676 and 776 ADENSA 876 and 976 3 All piping sizes are based upon 20 F temperature rise through the boiler For use of other A temperature rises through the boiler i e higher flow rates determine the flow rate and use SYSTEM Table for pipe sizes OSS WATER BOILER ae SUGGESTED PIPING CONNECTIONS J is 31 WATER RA Improper piping systems and or under 8 LINE sized piping can contribute to erratic boiler operation and pos sible boiler damage The piping system must be installed as 4 illustrated using the recommended minimum pipe sizes for the respective boiler Consult your Weil McLain distributor field salesman or field sales office or Weil McLain Applica tions Engineering Department before attempting to install FIGURE 9 STEAM BOILER PIPING 676 THROUGH 976 any alternate piping systems or smaller than recommended CONDENSATE pipe sizes S P Note A minimum of 24 from the water line to the bottom of the FIGURE 7 and the accompanying tables show the recom header is recommended Page6 Erecting Instructio
21. ns No 76 BOILER Weil McLain CONDENSATE RECEIVER CAPACITY Recommended Minimum Condensate Maximum Gross Receiver Capacity Condensate Output Gallons Feed Pump Pounds of 15 Min 30 Min 45 Min 60 Min Capacity Boiler of Steam Condensate Boiler Boiler Boiler Operation G P M at Number Per Hour Per Hour Operation Operation Operation Boiler 15 PSI 264 32 10 20 30 40 1 1 323 38 11 22 33 44 1 2 336 41 12 l 24 36 48 1 4 408 49 15 30 45 60 1 6 480 58 18 36 54 72 1 9 552 67 20 40 60 80 2 2 624 75 23 46 69 92 2 5 ALTERNATE STEAM BOILER PIPING ae To MINIMUM RECOMMENDED PIPE SIZES P a a FIXTURES Equalizer J 11 2 7 i f JALTERNATE x Z I COLD WATER 7 SUPPLY ya 24 Minimum from waterline to header Fa FIGURE 10 aoe lee STEAM BOILER PIPING AND HEADERS SUGGESTED PIPING CONNECTIONS WARNING 4 Improper piping systems and or under sized piping can contribute to erratic boiler operation and pos sible boiler damage The piping systems must be installed as illustrated using the recommended minimum pipe sizes for the respective boiler Consult your Weil McLain distributor field salesman or field sales office or Weil McLain Applica tions Engineering Department before attempting to install any alternate piping sys
22. o the inlet side of the circulator as illus trated in FIGURE 7 The supply and return piping and the compression tank are COMPRESSION TANK i Pa not supplied with the boiler but should be installed as illus Jo fF i i trated Controls are not shown in FIGURE 7 in order to more Ka Pa Fa clearly show the water boiler piping a ad In sizing the supply and return piping start with the mini i ra mum recommended pipe size and proceed at full diameter for G 10 times that diameter before making any reduction For ex i z ample a 3 return should not be reduced any closer to the boiler return tapping than 30 Horizontal expansion tank LO 4 piping must pitch upward at least 1 for each 5 feet of piping te from the boiler to the tank 759 Where system temperature modulation is achieved by RE TURN means of three way valves care must be exercised in piping ERRAT SIREAN the system to protect the boiler from thermal shock which could result from returning room temperature water at high FIGURE 7 i velocities to the hot boiler Where three way valves are em TABLE ployed consult Weil McLain Application Engineering De FOR KNOWN FLOW RATES partment for piping recommendations Primary secondary WATER SUPPLY RETURN pumping is preferred ee PIRE SIZE PIPE SIZE RECOMMENDED PIPING CONNECTIONS ery FOR STEAM BOILERS 10 16 GPM 1 fe w A 17 21 GPM SYSTEM 22 35 GPM 36 50 GPM A 51 76 GPM i q j High temperature r
23. ok at the water pressure FRONT INTERMEDIATE gauge and ascertain that the water test pressure has re mained constant FIGURE 5 8 Drain the boiler and remove plugs from those tappings which will be used Refer to the CONTROL TAPPING TABLE and FIGURE 5 CONTROL TAPPINGS Steam Water Safety Valve and or Skim Tapping High Limit Control Safety Valve Safety Relief Valve Combination High Limit and Low Limit Control Water Level Controls Low Water Cutoff Water Level Controls Low Water Cutoff Gauge Glass Try Cock Tappings Pressure Limit Control Pressure Op erating Control and Pressure Gauge Drain Combination Pressure Temperature Gauge Drain Piping To Compression Tank orl Automatic Air Vent Available on special request only Page 4 SUPPLY AND RETURN PIPING It is recommended that the system supply and return piping be installed and the piping connections be attached to the boiler before erecting the jacket or installing the controls to avoid any possible damage to the jacket or controls Recom mended piping arrangements for No 76 water and steam boil ers are shown in FIGURES 7 8 and 9 The minimum recom mended pipe sizes are listed for each piping arrangement The supply and return piping will not interfere with the erection of the boiler jacket w Erecting Instructions No 76 BOILER Weil McLain Onhwn N Front S
24. order to test the boiler seal CO readings must be taken in the firebox and at the flue outlet Lower readings at the flue outlet indicate infiltration of air into the firebox Locate the area of leakage and seal by cover ing the outer surface of the sealing rope with silicone sealant BURNER AND BREECHING DAMPER ADJUSTMENT eee FOR FORCED DRAFT FIRING Before firing the burner lock the breeching damper in the open position Start the burner and adjust the air band so that a clean yellow oil burner flame with slightly smoky tips or a clean gas flame is established Use combustion test instruments for final adjustment of the burner flame with the burner on high fire and the system wa ter temperature raised to approximately the design condi tions A smoke reading of a trace to No 1 on the Shell Bacharach scale is recommended with 1114 2 to 12 2 percent CO for No 2 fuel oil A CO reading of 9 to 10 percent is recom Page 11 mended for natural gas A test should be taken to assure that CO does not exceed 04 percent in the flue gases for gas firing For forced draft installations when the burner is on high fire and adjusted to the above conditions adjust the breeching damper to provide a positive pressure of approximately 0 10 inches water column measured at the test opening on the flue collar Secure the breeching damper by tightening the damper control swivels Use the 1 8 brass plug to close the test opening in the draft
25. proceeding to the next sec tion The boiler must be sealed gas tight wW WARNING 4 Use of chemical cleaners or sealants in any Weil McLain boiler is not recommended IN PARTIC ULAR PRODUCTS CONTAINING PETROLEUM DIS TILLATES MUST NEVER BE USED IN TYPE 76 BOIL ERS Page 3 SECTION SECTION a th N l i ott ALIGNMENT LUG Plt nt N41 t i I gt fo Pa J herpa i 7 ptt SOCKET fe real ni t H rl He jes the Coit Lp oo es ilil __ ELASTOMER i Ilf 1 SEALING RING i th l Joa doh il iy i war i f FIGURE 4 9 Four 2 x 4 4 studs are provided to secure the burner 10 11 12 mounting plate to the front section see FIGURE 6 Thread two 2 nuts on the rounded end of a 1 2 x 41 4 stud locking them together and thread the flat end of the stud into one of the four tapped holes located around the burner mounting plate opening in the front section a Remove the nuts from the stud Repeat steps a and b for the remaining three studs For BL 76 boilers hang one refractory retainer stain less steel plate over each mounting stud Make a small continuous bead of sealing rope adhesive in the groove around the burner mounting plate opening in the front section Position the 2 diameter by 58 long rope in the groove making sure the ends overlap at least 1 and install the burner mounting plate using the 1 2 washers and nuts provided
26. ring only by the fact that a manually adjusted breeching damper is not used Long horizontal breechings excessive numbers of elbows or tees or other ob structions which restrict the flow of combustion gases should be avoided Direct vertical venting from the flue collar to the outside will afford best performance at lowest total cost Use heavy gauge steel breeching to connect from the chim ney or vent to the flue collar on the boiler Install the baromet ric draft control in the breeching as close to the chimney as possible BURNER INSTALLATION Carefully unpack the burner from its shipping container and check the contents In case of shortage or damage notify the transportation company immediately The envelope of papers enclosed with the burner is to be used preserved and turned over to the owner and or the owner s repre sentative Slip the gasket over the end of the burner blast tube and push it forward until it engages the burner mounting flange Insert the end of the burner blast tube into the opening in the burner mounting plate Level the burner and firmly secure the burner mounting flange to the burner mounting plate us ing the bolts provided until a rigid installation is accom plished A gas tight seal must be maintained between the burner mounting flange and the burner mounting plate or damage to the burner air tube will result EZAN WIRING THE BOILER All wiring should be installed in compliance with the rules of
27. t oil application can also be fired with negative pressure in the firebox for natural chimney draft The boiler with pressurized firebox for forced draft firing can be used with a conventional chimney or stub vent The boilers with negative pressure in the firebox can only be used with a natural draft chimney On multiple boiler installations using one chimney consult Weil McLain Application Engineering Department for addi tional venting information Forced Draft When excess negative draft conditions can be expected to prevail in the breeching or when the chimney or stub vent height exceeds the published natural draft chimney height install the barometric draft control furnished with the boiler in the breeching as close to the chimney as possible Natural Draft Be sure the chimney is no smaller than the published height and cross sectional area Where the cross sectional area or the height of the natural draft chimney is smaller than the pub Page 1 lished dimensions or where excessive resistance to the flow of combustion gases can be expected it may be necessary to con vert the installation to forced draft by purchasing and install ing an induced draft fan The chimney must be at least the diameter indicated on the last page of these instructions under RATINGS to vent with natural draft BOILER FOUNDATION A boiler foundation is recommended where the boiler room floor is not level or where the boiler room floor cannot
28. tems or smaller than recommended pipe sizes FIGURES 8 and 9 and the accompanying table show recom mended piping connections and minimum recommended pipe sizes for No 76 steam boilers The supply and return steam piping is not supplied with No 76 steam boilers but should be installed as illustrated Controls safety valve low water cut off gauge glass etc are not shown on the steam piping dia grams in order to more clearly show the steam piping and Hartford Loop A minimum of 24 from the waterline to the header is recommended CAUTION The satisfactory operation of any steam heating boiler depends upon adequate return of condensate to the boiler to maintain a steady water level In rambling build ings with extended system piping nuisance shutdowns some times result when the condensate returning from the system lags behind the evaporation capacity of the boiler To main tain a steady water line avoid the introduction of excessive amounts of raw make up water To prevent nuisance shut downs due to a temporary low water level it is recommended that a low water cutoff and pump control condensate receiver and condensate boiler feed pump be installed Refer to the Condensate Receiver Capacity Table for recommended re ceiver sizes and condensate feed pump capacity ATTACHING THE JACKET The boiler should be pressure tested and the supply and re turn piping may be attached before the jacket is erected Make sure that only the
29. the National Electrical Code for installation in the U S A or Canadian Electrical Code C22 2 Part 1 for Canadian installa tions and any local state or insurance requirements or codes having jurisdiction Operating and safety circuit wiring must be No 14 gauge wire Power supply wiring to the burner must be No 14 gauge or heavier as required and shall have a prop erly sized fused disconnect switch Where the burner motor electrical current requirements are for voltages other than the control electrical current requirements be sure the proper voltage is supplied to the controls the burner motor and any auxiliary equipment Follow the separate burner manual and wiring diagram for wiring the burner and the boiler controls FUEL LINE PIPING Refer to the separate Burner Installation and Service Man ual and any local or national code requirements which may ap ply to sizing and installing the fuel line piping Page 10 Gas Piping The minimum inlet natural gas pressure required at the manual main shut off gas valve is listed in the Burner Instal lation and Service Manual shipped with the burner The gas pressure is for standard burners and is based on 0 60 specific gravity natural gas For other type gases or for burners with additional equip ment in the gas control assembly refer to the material list packaged with the burner for the minimum recommended in let gas pressure A main gas pressure regulator and a pilot line gas
30. tions have been erected Sealing rope adhesive is in a caulking tube and must be used with a caulking gun Make a 1 8 continuous bead of adhesive in the bottom of the curved sealing grooves lo cated around the perimeter of the section Position the 1 2 by 98 long sealing rope on the section by starting at the cleanout opening see FIGURE 2 Be sure the sealing rope is well seated at all points in the sealing grooves so that a gas tight seal will be maintained be tween the sections DO NOT APPLY adhesive to the op posing sealing grooves of the next boiler section Wipe the port openings with a clean rag to remove any grit from the machined surfaces Do not use any cleaner that contains a petroleum base distillate oil to clean ports Place the 71 2 and 31 2 elastomer sealing rings in the appropriate port openings see FIGURE 2 Combustion products and unburned oil vapors can cause failure of the elastomer sealing rings After the elastomer sealing rings have been set in the port openings of the sec tion make a s diameter continuous bead of silicone sealant around the outside of the rings Follow this proce dure for each sealing ring installed see FIGURE 3 Prepare the port openings in an intermediate section The TI intermediate sections if used must be installed in the order given in the SECTION ARRANGEMENT WITH INDIRECT WATER HEATERS table Note that 18 clearance must be provided on the left side
31. turer s instructions Two 2 pressure limit controls are furnished as standard equipment to perform low limit operating and high limit functions The pressure limit control used as the operator should be set according to the design requirements of the sys tem The pressure limit control employed for the high limit function should be set at least 2 PSIG higher than the operat ing control setting where possible 15 PSIG maximum allow able steam boiler pressure For additional information on the controls refer to the control manufacturer s instructions Water Boiler 1 Install the pressure relief valve in the proper tapping as indicated in the CONTROL TAPPINGS table and FIG URE 5 To avoid water damage or scalding the relief valve outlet must be piped to a floor drain or near to the floor Do not pipe the relief valve discharge to any area where freezing temperatures could occur 2 Install the pressure temperature gauge as indicated in the CONTROL TAPPINGS table and FIGURE 5 3 Where an optional 1 low water cut off is employed in stall the control in accordance with the CONTROL TAP PINGS table and FIGURE 5 using the fittings not fur nished Refer to FIGURE 11 for positioning If a low water cut off is to be used that is not dimensionally dia grammed in FIGURE 11 refer to the separate manufac turer s instructions for locating the control 4 Install the combination limit control as indicated in the CONTROL T
32. uel oil tank is above the level of the burner an anti syphon device must be used to pre vent the flow of oil in case of a break in the oil line If the top of the fuel oil tank is below the level of the burner use a check valve in the suction line on the burner side of the manual shut off oil valve nearest the tank An oil filter of the proper capac ity is recommended for all installations Copper tubing should be used in preference to iron pipe as it has less possibility for leaks and does not scale off on the in side ZG Flare type fittings are recommended The fuel oil piping from the tank to the burner should be sized no smaller than 1 2 O D copper tubing Where the fuel oil tank is located a considerable distance from the burner the fuel oil piping should be sized to reduce the friction loss An auxiliary fuel oil pump is recommended if the fuel oil suction line exceeds the length or lift published by the fuel unit manu facturer Erecting Instructions No 76 BOILER Weil McLain Connections to buried tanks must be made with swing joints to prevent the fuel lines from breaking in case the tank settles If the job requirements stipulate that iron pipe must be used swing joints made with elbows and nipples several inches long should be used on both the suction and return lines and located as close as possible to the tank The swing joints should be in stalled so they will tighten as the tank settles A manual
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