Weil-McLain P-35 Steam User's Manual
Contents
1. S RTA MAS ia Installation instructions P 35 STEAM OIL FIRED BOILER Weil McLain Company Inc GENERAL INSTRUCTIONS Open all boxes and check their contents In case of short age or damage notify the transportation company im mediately The side of the boiler to your right as you face the front of the boiler will be referred to in these in structions as the right hand side R H the side to your left will be refered to as the left hand side L H Note The installation must conform with the requirements of any focal state or insurance requirements or codes having jurisdiction AIR SUPPLY FOR BOILER ROOM Provisions must be made to supply sufficient air to the boiler room at all times for combustion for ventilation for operation of the barometric draft control and to pre vent less than atmospheric air pressures in the boiler room If there is a lack of combustion air in the boiler room the formation of soot can be expected to occur on the boiler flue passages In buildings of conventional frame brick or stone construction without enclosed utility rooms base ment storm windows or tight stair doors infiltration is normally adequate to provide air for combustion and for operation of the barometric draft control For installations in an enclosed utility room or boiler room without an outside wall a fresh air opening to the outside with a free cross sectional area of at least twice the area2. TANKLESS HEATER PIPING FLOW CONTROL VALVE Note Piping Connections not furnished Use brass plugs in tees and crosses to facilitate cleaning in hard water areas Figure 3 4 TANKLESS HEATER RATINGS dt Sad S Comindous Boiler Heater 100 F Average GPM 00 F shd Dettet control ember Number Temp R Temp Rise Tappings Tapping 35 5 29 a25 2w fow 3s s 29 aso s f w Pass s 375 seo Paass assz9 400 sso f w A Woil McLain ratings based on 60 P S I G domestic water pressure at Gallons of water hosted 3 per minute from 40 F to 140 F with 200 F boiler water temperat Continuous draw no Teco period CHIMNEY OR VENT The P 35 boilers are designed only for natural draft firing The natural draft chimney or vent must be at least of the size indicated on the last page of these instructions under Page 3 Ratings Data Dimensions Where the cross sectional area or height of the natural draft chimney or vent is smaller than the published dimensions or where excessive re sistance to the flow of combustion gases can be expected it may be necessary to purchase and install an inexpensive induced draft fan for best operation For elevations above 1 000 feet increase the chimney cross sectional area and height at least 4 per cent for each 1 000 feet above sea level The chimney or vent should extend high enough above the building or any other obstructions so that wind from an
3. and rating for the size P 35 boiler being installed MINIMUM CLEARANCES Allow a minimum clearance of at least 24 inches at the front of the boiler for servicing the oil burner controls For boilers ordered with a tankless heater allow a minimum clearance of 15 inches at the left side of the boiler for servicing the heater Provide at least 6 inches clearance at the back left side and right side of the boiler BOILER FOUNDATION The P 35 boiler is approved for installation on combustible flooring The boiler legs provide approximately one inch air space between the bottom of the boiler base and the boiler room floor or boiler foundation for natural aeration Where the boiler room floor is not level or where the boiler room floor will not support the weight of the boiler a boiler foundation will be required If the boiler founda tion is necessary it should be located to provide proper clearances around the boiler for installation of the supply and return piping fuel line piping barometric draft con trol breeching and an indirect water heater if used The location of the fuel oil supply tank should also be considered A level concrete brick or wood boiler founda iton is suggested and may be any desired height above the boiler room floor if head room permits The boiler founda tion should be constructed according to the chart and Figure 1 these dimensions allow about one inch clearance all around the boiler BOILER F
4. OUNDATION SIZES L Length of Foundation FRONT OF FOUNDATION LEVEL FOUNDATION AT LEAST TWO INCHES ABOVE FLOOR 2 MIN Figure 1 Farm MC 90A1 179WD Installation Instructions ten ees axed e om LOCATING THE BOILER Remove the wire bound crate and set the boiler on the foundation or on the boiler room floor as directed on the envelope containing these instructions Position the boiler as close as possible to the chimney and be sure to provide the minimum clearances around the boiler as indicated under Minimum Clearances When transporting the boiler to the desired position with the wire bound crate removed do not tip the boiler forward at any time as permanent damage to the burner may result HYDROSTATIC PRESSURE TEST OF BOILER The individual sections and the complete boiler has been hydrostatically pressure tested at the factory in addition the boiler has been factory fire tested The boiler should be pressure tested at the job location to insure that the water tight seal was maintained during shipment 1 Remove the shipping nipple from the supply outlet tapping at the top of the boiler and plug any necessary boiler tappings 2 Connect the water supply to the boiler and fill the boiler with water 3 Thoroughly inspect the entire boiler for water leaks 4 Thoroughly drain the entire boiler and remove plugs or fittings STEAM BOILER SUGGESTED PIPING CONNECTIONS Figure 2 and the accompan
5. ly Pipe Size Header Pipe Size Equalizer Pipe Size ua gr Boiler Number cr SL pene ee eee eR fesss o gt w EZ zo oo o oz o oo o w O Pass zo o oo oz w pees zo o odo o z w 24 minimum from water line to the bottom of header tory installed on the boiler The tankless heater piping should be installed as illustrated in Figure 3 1 It is recommended that a Flow Regulating Valve be installed in the cold water supply piping to the tankless heater as illustrated in Figure 3 in order to limit the water flow to the capacity of the heater The Flow Regulating Valve should be sized according to the intermittent draw rating of the tankless heater in the respective boiler size Refer to the Tankless Heater Rating Table for tankless lt lt heater capacities eae 2 An Automatic Mixing Valve should be employed and installed in the domestic hot water supply piping from the heater as illustrated in Figure 3 to permit regulation of the domestic hot water temperature o Page 2 ia pea Installation Instructions P35 STEAM OIL FIRED BOILER 2 Weil McLain Company Inc 3 In hard water areas it would be most dvisable to chemically soften the cold domestic supply water to the tankless heater to prevent subsequent lime build up inside the heater coils Good results can usually be obtained from a water softener which works on the ion exchange principle
6. ns enclosed in the envelope with these instructions Do not Company Inc use chemical cleaners in this boiler BOILER SERVICE AND MAINTENANCE Before leaving the job make sure the high limit control is operating properly by moving the indicator below the actual boiler water temperature while the thermostat con trol is calling for heat the burner should then stop Move the indicator to the normal setting and the burner should again start Test the action of the additional electrical safety controls using the preceeding procedures The boiler Operating Instructions contain information for the owner Review this information with the owner and or the owner s representative and be sure he receives all in structions Net ratings approved by ae RATINGS DATA D Buit to Radiator Mfrs All Boiler and Auxiliary Equipment subject to change without notice specifications wer i ey INTERMEDIATE Net 1 B R Ratings Gross Nett 1 B R 1 B R Net Output Output Sq Ft BTU Hr BTU Hr Steam Add suffix T for steam boiler ordered with tankless heater see tankless heater capacity chart tankless heater cannot be used with P 435 S need be be made boiler tNet 1 8 R Steam Ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothin loads Ratings are computed on an allowance factor of 1 333 An additional allowance shoul for normai pi
7. of the flue outlet of the boiler is recommended For each 1 000 feet above sea level increase the fresh air opening by 4 per cent The boiler room should be isolated from any area served by exhaust fans Do not install an exhaust fan in the boiler room IMPORTANT PRECAUTIONS Proper installation and wiring of the control equipment and proper adjustment of the oil burner is necessary for the successful operation of the oil fired boiler Follow the proper wiring diagram furnished inside the envelope which contained these instructions for connecting the elec trical supply wiring and for wiring any additional boilers controls The P 35 boiler has been factory fire tested however the burner must be properly adjusted according to the job conditions to assure efficient operation Use combustion test instruments to adjust the burner flame as outlined in the burner installation manual Adjust the burner to provide a smoke reading of a trace to a No 1 on the Shell Bacharach scale with 10 0 per cent to 10 5 per cent CO An over fire draft negative pres sure of at least 0 02 inches water column is necessary for proper combustion Refer to the last page of these instructions for the draft loss through the boiler for the size P 35 boiler being installed and add the desired 0 02 over fire draft to determine the draft required at the breeching connection Be sure the nozzle furnished with the burner is the proper type spray angle
8. ping loses and pick for usual piping loses and or pick up foads HEATER LOCATION Draft Loss Through Boiler inches Water Column Dimensions In Inches eal w7 Supp Outle Pipe Size L MYORONIC a WEIL M LAIN COMPANY INC gt MICHIGAN CITY INDIANA BOivisSton Page 4
9. tructions packaged with the control Drill a small hole in the breeching just ahead of the boiler smoke collar to facilitate measuring the CO and breeching draft and for taking the smoke reading BURNER AND SAFETY CIRCUIT WIRING The burner motor ignition transformer low water cut off burner primary control and limit control are prewired at the factory If any additional electrical safety controls are employed No 14 gauge wire may be used The power input supply wiring to the burner should be No 14 gauge wire or heavier as required and should have a properly BURNER ADJUSTMENT Refer to the burner installation and service manual for starting the burner Be sure the fuel oil tank and fuel line piping are sized correctly and installed as directed Start P 35 STEAM Weil McLain OIL FIRED BOILER Installation Instructions the burner and adjust the air band so that a clean yellow flame is established avoiding smoky tips After the boiler starts steaming use combustion test in struments for final adjustment of the burner flame A smoke reading of a trace to No 1 on the Shell Bacharach scale is recommended with 10 0 per cent to 10 5 per cent CO Adjust the barometric draft control to provide 0 02 negative over fire draft CLEAN THE NEW STEAM BOILER New steam boilers must be cleaned properly previous to or during the first few days of operation Follow the clean ing recommendations listed on the Operating Instructio
10. y direction will not strike the chimney or vent from an angle above horizontal and thus produce down drafts Unless the obstruction is of great magnitude it is the usual ex perience that a chimney or vent extended at least 2 feet above flat roofs or 2 feet above the highest part of wall parapets and peaked roofs which are within 30 feet will be reasonably free fram down drafts The chimney should be examined before the connection of the boiler to be cer tain that it is properly constructed clear and will freely conduct the products of combustion to the atmosphere BREECHING ERECTION In entering the chimney the breeching connection must be sufficiently above the extreme bottom of the chimney to avoid any danger of stoppage The breeching connection must not project beyond the inner wall of the chimney A thimble or slip joint may be used to facilitate removal of the breeching for cleaning Do not place a damper or any other obstruction in the breeching The breeching slope upward toward the chimney at least 1 4 inch per lineal foot of breeching and must be at least of the same equivalent diameter as the published dimensions of the rectangular or square chimney Long horizontal breech ings excessive numbers of elbows or tees or other ob structions which restrict the flow of combustion gases should be avoided Install the Barometric Draft Control in the breeching between the boiler and the chimney ac cording to the manufacturer s ins
11. ying chart shows the recom mended piping connections and minimum recommended pipe sizes for P 35 steam boilers The supply and return piping is not furnished with the boiler but should be in stalled as illustrated Controls steam safety valve low water cut off gauge glass etc are not shown on the piping diagram in order to insure clarity of the steam piping 1 Connect the steam supply riser header and equalizer around the boiler as shown in Figure 2 To insure proper performance the bottom of the supply header must be at least 24 inches above the boiler water line a Connect the system supply piping to the header as shown in Figure 2 b Connect the condensate return piping to the equal izer piping 2 inches below the boiler water line 2 Connect the cold water fill supply piping close to the boiler in the condensate return piping 3 Connect the steam safety valve outlet to a floor drain or near to the floor Do not pipe the safety valve discharge to any area where freezing temperatures could occur TANKLESS HEATER HOOK UP Where a tankless heater was ordered with the P 35 boiler the heater and temperature operating control will be fac OIL FIRED BOILER aaa Weil McLain _ lt _ Company tinc PoR RECOMMENDED PIPING CONNECTIONS _FOR STEAM BOILERS TO SYSTEM lt SHORT NIPPLE ZCONDENSATE A RETURN 4 Figure 2 STEAM BOILER PIPING MINIMUM RECOMMENDED PIPE SIZES Supp
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