Weil-McLain PD Gas Series 3 User's Manual
Contents
1. fF z LEFT SIDE Number and size of Water Flows in Return in RIGHT SIDE Figure 2 DIMENSIONS Boiler Purger Circu Propane Number trol 1 1 1 1 52 3 4 1 1 2 3 4 1 1 54 7 8 1 14 54 7 8 1 14 57 3 4 1 14 57 3 4 RATINGS AND DATA Net Ratings eA NN OO WW A DB Minimum A G A A G A Gross Net I B R Sq Ft A S M E Input Output Ratings 150 BTU Relief Valve Flue Boiler BTU BTU BTU Emission Capacity Dia No Per Hour Per Hour Per Hour Per Sq Ft BTU Per Hour Inches 50 000 40 000 30 000 40 000 75 000 60 000 45 000 60 000 100 000 80 000 60 000 80 000 125 000 100 000 75 000 100 000 150 000 120 000 90 000 120 000 175 000 140 000 105 000 140 000 200 000 160 000 120 000 160 000 225 000 180 000 135 000 180 000 z Net 1 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 Exception An additional allowance should be made for unusual piping and pick up loads Chimney heights should be 20 feet In special cases where surrounding conditions permit chimney height may be reduced to 10 feet IMPORTANT Compression Tank Sizing No 109 Extrol furnished for P D 3 thru P D 7 No 110 Extrol furnished for P D 8 thru P D 10 The expans2. inches for propane SIZE OF PIPING TO GAS BOILERS In determining the size of gas pipe the following factors should be considered a Length of pipe and number of fittings b Maximum gas consumption to be provided for including possible future expansion c Allowable loss in pressure from meter out let to boiler This is specified as three tenths of an inch water column The volume to be used in cubic feet per hour shall be determined whenever possible directly PIPE DELIVERY SCHEDULE CAPACITY OF PIPES IN CUBIC FEET OF GAS PER HOUR Length of Pipe in Feet P84 from the BTU ratings of the boiler which will installed and the heating value of the gas to we used To obtain the cubic feet per hour divide the total BTU input of the boiler by the BTU heat ing value per cubic foot of gas For 604 BTU gas allow 1 7 cubic feet and for nat ural gas allow 96 cubic feet for each 1000 BTU See table below for determining the capacity of pipes of various diameters and lengths ADDITIONAL LENGTH OF PIPE TO BE ADDED FOR EACH ELBOW OR TEE BEND IN THE LINE Additional e Feet RPT Flow determined by Dr Pole s Formula Specific Gravity 60 Pressure Loss 3 10 water vo Installation Instructions TYPE P D GAS SERIES 3 Weil McLain Boiler STARTING UP SYSTEM FOR ALL GASES A The following prelighting steps are recommend ed to insure all around safety 1 Fill system
3. If the boiler is to be located in a confined space clearance should be provided on all sides as shown in Figure 4 for alcove installation The flue pipe must not be closer than 6 from combustible material A factory installed air cushion tank and air elimination system is provided with the P D boiler The expansion volume is suitable for boilers installed in one story houses or two story houses with non ferrous baseboard sys tems When an additional air cushion tank is required the tank may be connected to a tee in the supply or retum line close to the boiler see Page 2 PIPING CONNECTION TO THE HEATING SYSTEM The piping to the heating system should be made at this time Do not bush the flow or re turn tappings use reducing fittings when neces sary to make the proper connection The P D boiler is supplied with a Purger Trol with two supply tappings The supply to the system may Page 3 MINIMUM CLEARANCE FOR ALCOVE INSTALLATION Note See Figure 2 on Page 2 for minimum ceiling clearance when installed in larger rooms Tor view SIE VIEW APPROVED FOR INSTALLATION ON COMBUSTIBLE FLOORING WHEN PART D P 26 A IS INSTALLED UNDER THE ENTIRE BOILER See Table on Page 2 for Dimensions Figure 4 be used from both sides or one side The un used supply tapping must be plugged with the plug supplied No flow control device is re quired on this boiler because the circulator runs continuously until it reache
4. unit will start 2 When unit has operated for about 5 to 10 min utes allowing the boiler water temperature to rise to about 120 to 130 F then turn the high limit control setting below the boiler water temperature The bumers should go out then turn the high limit control up above the boiler water temperature the burner should ignite Then set the high limit control to the desired maximum boiler water temperature 3 Set the room thermostat to desired room temp erature 4 Make sure that the primary air shutters are tightened in a fixed position so that they will not be subject to an accidental change in position For additional information on controls see con trol sheets supplied with boiler WHEN BOILER IS USED WITH REFRIGERATION SYSTEM When boiler is used in connection with refrigera tion systems it shall be installed so that the chill ed medium is piped in parallel with the heating boiler and with appropriate valve to prevent the chilled medium from entering the heating boiler When hot water heating boilers are connected to heating coils located in air handling units where _they may be exposed co refrigerated air circulation he boiler piping system shall be equipped with tlow control valves or other automatic means to prevent gravity circulation of the boiler water dur ing the cooling cycle TANK SHUT OFF VALVE CIRCULATOR SUPPLY PIPE HEATING BOILER RETURN PIPE FROM COMBI
5. with water See home owners card for instructions 2 Turn off main electric switch 3 Purge the air from the main gas line 4 Check all piping for gas leaks CAUTION Allow boiler to ventilate for 5 minutes after checking piping for gas leaks TO CHECK FOR GAS LEAKS USE A SOAPY SOLUTION DO NOT USE A FLAME Liability for damage done through the use of a flame when testing for gas leaks cannot be assumed by the manufacturer B Start up Boiler as indicated in the following steps SHUTTING OFF BOILER 1 Turn manual gas cock to the off position 2 Turn off main boiler electrical switch STARTING UP BOILER Follow the lighting procedure outlined on the Oper ating Instruction Plate mounted on the jacket in terior panel CAUTION Make sure manual gas cock knob has been in off position for at least 5 minutes before lighting THERMOSTAT HEATER SETTING The Thermostat Heater Setting must be adjusted to match the current requirements of the primary control used It may be necessary to raise the Thermostat Heater Setting to provide a minimum on period of two 2 minutes in mild weather to assure optimum system operation To lengthen operation move the Heater Indicator to a higher setting as indicated by the direction of the arrow on the Heater Indicator Scale ADDITIONAL INSTRUCTIONS Important Before leaving job make sure unit checks electrically 1 Set the room thermostat above room tempera ture so that
6. C INLET water NSTRUCTION PI CONNECTION WIRING PLAT BE gt JUNCTION sox ALCOVE KNOCK OUT FOR ARANGE PLATI 1 f SV ELECTRICAL SUPPI AIR CUSHION COMBINATION VALVE PhO LUR NIF OLA x Fs A DOOR Figure 5 NOTE PD 9 and PD 10 boilers used with 800 950 BTU gases require the V81E gas valve in place of the combination Gas Valve a pressure regulator manual main shut off valve pilot cock and a pilot silter if required by utility will be required with the c Remove the cap at the Right Side of the gas mani fold Disconnect the gas control assembly from the Left Side of the gas manifold and secure to the Right Side by means of the union Connect the thermocouple lead to the gas valve Do not tighten more than 1 4 turn be yond finger tight Connect the pilot tubing to the gas valve Do not tighten more than one full turn beyond finger tight Replace the cap at the Left Side of the gas manifold and be sure a gas tight seal is maintained 3 Connect the gas line to the meter Install any additional manual main shut off valve not sup plied when required by local utility company A drop leg must be installed at the inlet of the gas connection to the boiler te satisfy A G A requirements d Where the local utilities require that the drop leg be extended co the floor place an appro m priate length of pipe between che cap and cee e Any piping needed to comply with local codes mus
7. Installation Instructions a GENERAL INSTRUCTIONS Locate the boiler as close as possible to the chimney taking care to provide ample clearance for access to the piping It is required chat a clearance of 24 be allowed at sides where ser vicing will occur and 18 allowed at a side where passage is necessary to another side re quiring servicing or cleaning Minimum clearance on remaining sides should be no less than 6 See Page 3 for permissable minimum clearance for alcove installations NOTE Installations must conform with the re quirements of local utilities and those of other local authorities having jurisdiction CHIMNEY OR FLUE The masonry chimney or Type A flue to whch the boiler is connected must have a cross sectional area not less than that of the cross sectiona area of the draft hood The chimney should extend at _ least cwo feet above che highest part of the roof o that wind from any direction will not strike the flue or vent from an angle above horizontal and not produce a positive static pressure Chimney linings should be used when required by national state or local building codes Vitreous tile lin ings with joints which prevent retention of mois ture and linings made of non corrosive materials are advantageous Advice regarding recommended practice and material for flue connections and chimney linings can usually be obtained from the local gas company and should be given careful consideratio
8. NATION HEATING amp COOLING UNITS Figure 6 Page 6 a a
9. ion volume is suitable for boilers installed in one 10 boilers an additional 30 Extrol will be required story or two story houses with non ferrous baseboard systems 3 Converted gravity systems may require additional compression Please note the following as a guide to other systems tank capacity l For systems employing cast iron radiators an additional 15 4 When additional compression tank capacity is required do not Extrol will be required on P D 4 5 6 7 8 9 and 10 boilers replace the tank furnished on the boiler package with a larger 2 For systems with cast iron baseboard an additional 15 Extrol tank Instead an additional tank should be connected to a tee will be required on P D 4 and 5 boilers For P D 6 7 8 9 and in the supply or return line close to the boiler NOTE Where the boiler is to be used with a radiant pane system or other low water temperature applications a boiler bypass piping arrangement should be used to assure optimum system operation Page 2 Installation Instructions TYPE P D GAS SERIES 3 Weil McLain Boiler pen 7 wf the boiler is to be erected on a combustible floor our heat shield Part No D P26 A must be placed under the legs of the boiler base and on the floor to comply with A G A approval See Figure 3 n e _ a a AMAA AAA WN AW AAA Figure 3 INSTALLING THE BOILER Position the boiler near the chimney and on a level concrete foundation
10. n In the event a Type B or Type C vent is used the instructions relative to size and height contained in the Manual ASA Z21 30 1959 American Standard Installation of Gas Appliances and Gas Piping should be followed The chimney should be examined before the gas boiler is in stalled to ascertain that it is properly construct ed clear and will freely conduct the products of combustion to the outer air Flue piping should not extend beyond the inside wall of the chimney Do not place a damper or any other obstruction in the flue pipe The flue pipe should slope up toward the chimney at least 1 4 per foot and nust be the same size as the outlet of the draft hood Where two or more appliances vent into a common flue the area of the common flue should be at least equal to the area of the largest flue or vent connector plus 50 of the area of the addi tional flue or vent connector TYPE P D GAS SERIES 3 Page 1 Weil McLain Boiler AIR SUPPLY FOR BOILER ROOM Provisions must be made t supply sufficient clean air to the boiler room at all times In build ings of conventional frame brick or stone con struction without enclosed utility rooms basement storm windows or tight stair doors infiltration is normally adequate to provide air for combustion and drafthood dilution For installations in utility rooms without an outside wall clean fresh air ve tilation to the rooms should be provided by placing an o
11. pening at the top and bottom of the room allowing a minimum of 1 square inch of open ing for each 1000 BTU per hour input with not less than a 100 square inch opening in each location In confined areas without good ventilation open ings to the outside should be provided with a min imum free area of 1 square inch per 4000 BTU per hour of boiler input rating IMPORTANT PRECAUTIONS Proper installation and adjustment of burners and control equipment are important for the successful operation of the gas boiler The operating instruc tion plate furnished with the boiler is mounted on the inner jacket panel Read the instructions very carefully before starting the gas boiler BOILER FOUNDATION A level concrete or brick foundation is strongly recommended and should be from two to a maxi mum of six inches above floor level if head room permits MINIMUM FOUNDATION DIMENSIONS Boiler Length L Boiler Length L No inches No Inches 22 These dimensions allow about 1 inch clearance all around the boiler peas LEVEL FOUNDATION AT LEAST 2 HIGHER THAN FLOOR 25 MIN Figure Form No MC 1536 465 lt gt TYPE P D GAS SERIES 3 Weil McLain Boiler Installation Instructions 9 Minimum clearance from ceiling for el bow installations All flue pipes must be 6 from combustible material See Figure 4 on Page 3 for clearances required when installed in confined space
12. s the circulator control setting The return line is piped directly to the flange on the circulator The P D boiler is supplied with a fill trol valve When the cold water supply is connected to the fill trol valve it will automatically fill the sys tem at a reduced pressure and maintain mini mum system pressure Before connecting the water supply to the fill trol follow the instruc tions on the tag attached to the handle of the _ Fill trol valve DRAFT HOOD Install che draft hood to che outlet of the cole lector hood at the top of the jacket The draft hood must be installed as it is received without any alterations CONNECT THE GAS SUPPLY TO THE BOILER Determine whether the gas supply is to be piped to the Right Side or Left Side of the Boiler 1 If the gas supply is to be piped to the Right Side of the boiler remove the knockout disc from the Jacket Right Side Panel and proceed to Step 3 If the gas supply is to be piped to the Left Side of the boiler a Remove the knockout disc from the Jacket Left Side Panel b Remove the thermocouple lead and the pilot tubing from the gas valve See Size of Piping to Gas Boilers on Page 5 Installation Instructions TYPE P D GAS SERIES 3 Weil McLain Boiler COMBINATION DRAF OD HIGH LIMIT AND PRESSURE TEMPERATURE SIRCULATOR CONTROL f ALTITUDE GAUGE Il A RATING PLATE z SUPPLY TAPPING EITHER SIDE OPERATING
13. t be furnished by installer Check all gas connections for leaks use a soapy solution do not use a flame Liability V81IE gas valve Pilot filter built into combination valve body For Propane Gas valve and pressure regulator is supplied with a sep arate manual main shut off valve pilot cock and pilot filter if required by utility a combination gas for damage done through the use of a flame when testing for gas leaks cannot be assumed by the manufacturer WIRING AND CONTROL FUNCTION The boiler is shipped completely wired The wir ing diagram is on a plate located on the inner pan el of the jacket The P D is supplied with a dual control for high limit and circulator function The high limit is set at che factory for 210 but may be changed according to the design temperature of the heating system The circulator control setting should be set at 1400F When the thermostat calls for heat che burner will ignite and continue to operate until the room tem perature is satisfied or the boiler water tempera ture reaches the high limit setting at which time the burner will go out The circulator will continue to operate until the boiler water temperature rea ches the setting of the circulator control The pump operates continuously until the water temperature reaches the setting of the circulator control at which time it will stop running This type of system is fully automatic The power supply must be 115
14. volts which must be connected to the white and black wires in the junction box located on the jacket Page 4 Installation Instructions TYPE P D GAS SERIES 3 Weil McLain Boiler ADJUSTING THE BURNERS Proper adjustment of the primary air shutters on the burners is essential for correct performance Avoid a hard flame that burns close to the burners by proceeding as follows with each shutter 1 Adjust the primary air shutter by closing until yellow tips appear on the flame 2 Then open the shutter very slowly until the yellow tips just disappear from the flame 3 Lock the shutter in this position by tightening the shutter retaining screw securely Measure the gas input to the boiler by reading the meter Be sure all other appliances connected to the same meter are shut off x 60 minutes hr x heating value of gas in BTU cu fe Cu ft of Gas Minutes at meter BTU Hr boiler input as shown on boiler name plate If it is within 5 adjust pressure regulator to obtain the desired flow stem for adjustment is under the cap on top of the regulator TURN STEM CLOCKWISE TO INCREASE AND COUNTER CLOCKWISE TO DECREASE THE RATE If rate is more than 5 off of rated input change orifice sizes Check the burners again and re adjust the flames if necessary NOTE For proper aspiration the manifold gas pressure should be about 2 1 2 inches of water column for manue factured gas 3 1 2 inches for natural and 11
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