Weil-McLain 550-141-829/1201 Boiler User Manual
Contents
1. ji pun mm met m ANIHIA ABOL padder adt aar zq ure uo pavpum s st 131230 auy AZON a TE i i Veyan gt wn S s IR SNTBIM AHOLI JWA 021 ar 2 Sit UNUUNU 1 j 2 TEH JYE ag aouegdde sun porpddns sv odia purmo aqui JO JJ UE e Wornrurojur unge Buneiodo anasini 9 gt SINUM 0712913 NA QEL m o ayy pasped suononursur al EM jo LE ETIPRETRELE2H ssE 7 aq X i i a ipo qv SD Md Taare adu psn un orm uripeug spuaurarmbor apoo pro 4o apers gt ru tapo Aur pur aourpaooor aq pantu duris ry MOSS LR 20 suappnupsu gas NOLLISOd nari moys uo aA EA E Seq jeu joujuos i a penu dung jn eg qM sawung 3OLLON M M SEE Guy yauas 10 aa2. pw 2 e o nia ll Burner Opening oi INTR 911 241 3 500 A Front NUMBER Thu 182 6 La 4 103 2 BOILER P SteamSupply MODEL T Piping 3 9 SGO Side with Burner Ratings s SGO GOLD OIL STEAM BOILER RATINGS 1 STEAM I B R NET I B R MINIMUM BOILER BOILER BURNER DOE HEATING RATINGS 5 I B R CHIMNEY OUTLET WATER MODEL CAPACITY 4 k T ROUND CONTENT BOILER NUMBER GPH 3 MBH 2 GAL 8 IN W C 9 rn eS om mer Ds pom scos is mo se i m o r i M meris p pop er ome ceos im m pa es Substitute P for completely assembled packaged steam boiler without burner SGO 3 through SGO 6 only Substitute A for boiler only for use with approved burners as listed with I B R Available only as an A unit 1 560 boiler designed with convertible vertical and horizontal flue outlet 2 MBH refers to thousands of Btu per hour 3 Based on 140 000 Btu gal 4 Based on standard test procedures prescribed by the United States Department of Energy at combustion condition of 13 0 CO2 for SGO 3 and 13 5 for SGO 4 through 7 5 Met I B R ratings are based on net installed radiation of sufficient quantity for the requirements of th
3. and carbon monoxide emissions which can lead to severe personal injury or death Roc Install jacket sizes 7 through 9 only Before installing jacket remove burner mounting door See jacket instructions for details Install boiler controls See Control Tapping Table and FIGURE 4 on page 10 and FIGURE 5 or 6 on page 11 to install controls 1 Do not use Teflon tape to install probe type low water cutoff it will cause low water cutoff lo work improperly Install tankless heater control if tankless heater is used If not furnished use operating control with maximum 10 F differential Make sure gauge glass is last control installed to prevent breakage Affix CP number label s on jacket front panel Flue Collector Hood Sealing Rope with Adhesive Tape CONTROL TAPPING TABLE SIZE FUNCTION A Skim Tapping 22 34 SupplyPiping sizes 3 9 Supply Piping sizes 9 Bi Plugged _ Return Piping EI amp E2 A Float LWCO x Tm team Pressure Gauge and Limit _ Control when using Probe LWCO _ E2 Plugged when using Probe LWCO E Drain Valve _ Steam Pressure Gauge and Limit Control yor using Float LWCO Plugged when using Probe LWCO Probe LWCO Plugged when using Float LWCO Relief Valve Gauge Glass Indirect Fired Water Heater Hot Water Baseboard Supp Operating Control for Tankless Heater sizes 6
4. National codes where applicable Canada Canadian Standards Association CSA B139 Installation Code for Oil Burning Equipment CSA C22 1 Canadian Electrical Code Part One Applicable local or provincial codes Before selecting boiler location Check for nearby connections to System water piping Chimney See pages 12 13 Boiler can be top or back vented Combustion and ventilation air supply See page 5 Oil supply See page 24 for oil line routing Electrical power Check area around boiler Remove any combustible materials gasoline and other flammable liquids AWARNING Failure to keep boiler area clear and free of combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage m sy Top View Provide clearances around boiler see FIGURE 1 woTieec Jacket cap must be in place NOTICE boiler to avoid requiring an 18 minimum clearance from back or top of boiler to combustible material Minimum clearances from vent pipe to combustible material 6 inches doublewall vent 18 inches Singlewall vent NO TICE Flue pipe clearances must take precedence over jacket clearances Recommended service clearances 24 inches Front and top 6 inches Left side back and right side A 15 inches Left side with tankless heater 12 inches
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6. EN Int Jacket cap must be in place NOTICE on boiler to avoid requiring an 18 minimum clearance from back of boiler to combustible material p Check level Shim legs if needed Check for secure placement of insulation on target wall chamber floor and burner door 5 Visually check a Flue collector hood seal b Burner mounting door seal A WARNING Obtain gas tight seal to prevent possible flue gas leakage and carbon monoxide emissions which can lead to severe personal injury or death P Tankless heater if used 1 Remove tankless heater knockout in left side of jacket panel and for SGO 6 only tankless heater control knockout Remove tankless heater cover plate and gasket Install new gasket and tankless heater over studs around opening Secure with 78 nuts Install tankless heater operating control where shown on page 18 If not furnished use operating control with maximum 10 F differential Perform hydrostatic pressure test l Remove steam pressure gauge furnished with boiler Install water pressure gauge for test only Be sure gauge can handle test pressure Install air vent in tapping on top of boiler Remove pressure control and low water cutoff Plug tappings Plug supply and return tappings Drain valve is already factory installed Fill boiler Vent all air Pressure test boiler at 45 55 psig Do not leave boiler unattended A WARNING Cold water fill can expand an
7. Right side for burner door swing radius A Ceiling 6 18 187 24 Recommended Service Clearances FIGURE 1 Before Installing Boiler conmnueo Provide air for combustion and ventilation L Adequate combustion and A WARNING ventilation air e Assures proper combustion e Reduces risk of severe personal injury or death from possible flue gas leakage and carbon monoxide emissions Do not install exhaust fan in boiler room Older buildings with single pane windows minimal weather stripping and no vapor barrier often provide enough natural infiltration and ventilation without dedicated openings New construction or remodeled buildings are most often built tighter Windows and doors are weather stripped vapor barriers are used and openings in walls are caulked As a result such tight construction is unlikely to allow proper natural air infiltration and ventilation Follow state provincial or local codes when sizing adequate combustion and ventilation air openings In absence of codes use the following guidelines when boiler is in a confined room defined by NFPA 31 as less than 7200 cubic feet per 1 GPH input of all appliances in area A room 8 ft high x 83 5 ft x 33 5 ft is 7200 cu Provide two permanent openings one within 12 inches of ceiling one within 12 inches of floor Minimum height or length dimension of each rectangular opening should be at least 3 inches
8. This Manual Includes Installation Start Up Boiler Parts Installer Make sure this is the correct manual for the boiler Verify boiler model on rating label Leave all documentation received with boiler and burner with unit for future reference User Boiler and burner must be installed and serviced by qualified service technician Part No 550 141 829 1201 Hazard Definitions The following terms are used to bring attention to the presence of hazards of various risk levels or to important information concerning product life A DANGER Indicates presence of hazards that will cause severe personal injury death or substantial property damage if ignored A WARNING Indicates presence of hazards that can cause severe personal injury death or substantial property damage if ignored CAUTION Indicates presence of hazards that will or can cause minor personal injury or property damage if ignored TI C E Indicates special instructions on installation operation or maintenance that are important but not related to personal injury hazards Symbol Definitions The following symbols are used to indicate sequence of installation for P Factory assembled packaged boiler block jacket and controls Sizes 3 through 6 only Factory assembled block no burner Sizes 3 through 6 with jacket installed steam trim controls shipped separately Sizes 7 through 9 with jacket and steam trim contro
9. _ p J 1294002510 jap aanas puerey peapa T Hd i i i x i z 3 Hane quare senpia wur 2 HOLING dee T Ua a o O m nae avo z A CLP E jogjuo2 00209 Connect Wiring Probe Type Low Water Cutoff Pressure Control Wiring Harness 2 Tankless Heater Control Wiring 3 Burner Disconnect Plug 4 Burner Wiring Harness 5 Low Water Cutoff Wiring Harness not furnished on A Boilers 0116 00275 Boiler Wiring for Probe Type LWCO FIGURE 14 23 Connect Oil Piping General oil piping requirements e Location and installation of oil tanks oil piping and burners must follow 31 Standard for the Installation of Oil Burning Equipment Canada CSA 8139 Installation of Oil Burning Equipment Local codes and regulations Information provided with burner and fuel pump If any part of fuel oil tank is above level of burner an anti siphon device must be used to prevent flow of oil in case of oil line break e Support oil lines as required by codes see local codes for appropriate arrangement and piping of filter control valves etc back to oil
10. 1 Refer to burner manual for start up 2 Allow boiler to heat to design condition 3 Using combustion test equipment adjust burner for a between 11 and 12 and 0 smoke b 0 01 to 0 02 W C draft in combustion chamber To connect SGO boilers to indirect fired water heaters Install and wire per water heater manual provided with water heater If boiler already has a tankless heater installed e Remove tankless heater and install cover plate OR e Leave tankless heater installed Drain coil and remove piping Do not plug holes in tankless heater front plate p d Pest 7 000 NOTICE Repair parts must be purchased through Weil McLain for the specific boiler as indicated in the list below Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation es Weil McLain oO Lescriptior art 5 700 5 700 06 00 070 5 700 386 700 852 386 700 85 56 UU 66 00 665 395 700 656 386 700 668 00 659 965 100 570 26 700 6 00 340 26 700 34 700 44 A 34 389 900 103 35 700 9 70 0 358 330 054 304 330 05 4 300 386 700 359 460 039 867 590 735 105 590 739 109 386 700 344 591 706 214 Includes flue cap assembly rope and hardware for installation 20 514 4 Th 196 9 a i 3 1 95 3 BOILER MODEL NUMBER pee 904 881 25 mu
11. 9 or uz Operating Control for Indirect Fired Water Heater sizes 3 9 y Operating Control for Tankless Heater Located in heater plate sizes 3 5 Install burner also refer to instructions packed with burner J MunTinE X Burners designed for use with NOTICE Weil McLain 68 boilers must not be used on GOLD Oil boilers Contact individual burner manufacturers for GOLD Oil applications For P SGO and A SGO boiler 1 Secure universal mounting flange and gasket to burner mounting door Use three bolts provided 2 Secure burner on flange with three bolts 3 Position burner so end of air tube is level to 115 tilt down toward chamber Open door to verify burner position End of air tube should be flush to 1 4 recessed from inside wall of burner door refractory Check for secure placement of insulation on target wall chamber floor and burner mounting door Securely close door Front Section Back Section Control Tapping Location FIGURE 4 Steam Pressure Control Steam Pressure Gauge Siphon yid Gauge Glass eater and Cocks Location 5006 9 Tankless _ Heater Control Location Float type Low Water Cutoff Drain Valve Steam Boiler Controls With Float Type LWCO Optional Tankless Heater Control FIGURE 5 Steam pressure Steam pressure SGO 3 to SGO 5 tankless robe type heater control x L low water SGO 6toSGO 4 9 tankless b heater
12. When inside air is used each opening must freely connect with areas having adequate infiltration from outside Each opening should be at least 140 sq in per 1 GPH input 1 sq in per 1000 Btu input of all fuel burning appliances plus requirements for any equipment that can pull air from room including clothes dryer and fireplace When outside air is used connect each opening directly or by ducts to the outdoors or to crawl or attic space that freely connects with outdoors Size per below e Through outside wall or vertical ducts at least 35 sq in per 1 GPH input 1 sq in per 4000 Btu input of all fuel burning appliances plus requirements for any equipment that can pull air from room including clothes dryer and fireplace Through horizontal ducts at least 70 sq in per 1 GPH boiler input 1 sq in per 2000 Btu input of all fuel burning appliances plus requirements for any equipment that can pull air from room including clothes dryer and fireplace e Where ducts are used they should have same cross sectional area as free area of openings to which they connect Compensate for louver grille or screen blockage when calculating free air openings Refer to their manufacturer s instructions for details If unknown use Wood louvers which provide 20 25 free air Metal louvers or grilles which provide 60 75 free air Lock louvers in open position or interlock with equipment to prove open b
13. exists contact your Weil McLain distributor or sales office before continuing installation Non Packaged SGO 7 8 amp 9 install flue collector hood see FIGURE 3 AWARNING Obtain gas tight seal to prevent possible flue gas leakage and carbon monoxide emissions leading to severe personal injury or death a Thread tinnerman clip on screw so that clip fits snugly in notch of hold down lug Screw must not turn Remove paper on sealing rope Starting at back section near flue collar position sealing rope around top of block with adhesive side to sections Do not stretch rope Make sure rope ends meet Trim excess rope Position flue collector hood on top of boiler sections and over screws and clips as shown in FIGURE 3 Install washers and nuts Tighten nuts until collector hood makes contact with tinnerman clip Back flue outlet boiler Position flue cap and strap over opening in flue collector hood Make sure rope in cap is in place and in good condition Tighten strap to hood with screws provided Top flue outlet boiler Position flue cap and strap over opening in back section Make sure rope in cap is in place and in good condition Tighten strap to boiler with screws provided in section Install remaining screws in holes in flue collector hood 4 Check level Shim legs if needed Install Non Packaged Boiler occ Tankless heater if used l SGO 3 through 6 remove knockout in left
14. split the assembled block for easier handling see FIGURE 3 a Open burner mounting door and using utility knife slit floor insulation at joint to be separated Remove 5 draw rod and the longest draw rod from each side Pull block apart Save draw rods nuts washers and sealing rings for reassembly Move divided block to location Clean port openings with clean rag A Do not use petroleum based A CAUTION compounds to clean openings Damage to system components can result causing property damage Place rings in port openings If ring slips out of groove stretch ring gently for several seconds then place in groove Position sections so aligning lugs fit into sockets of next section Make sure sealing rope is in good condition and in position Oil threads on draw rods Install washer and nut on end to be tightened Use nut only on other end h With wrench at washer nut end uniformly tighten nuts starting with 5 2 rod at large port 51 rod at small port bottom long rod and finally top long rod Torque on both 5 2 rods and bottom long rod should be 50 60 ft Ibs long top rod should be 20 25 ft Ibs Do not back off nuts Metal to metal contact should be made around port openings If gap does exist it should be less than 020 Check with feeler gauge If Sap around port openings exceeds 020 check for dirt on port openings sockets or misaligned lugs If corrections are made and gap still
15. tank e Make tank connections with swing joints or copper tubing to prevent breaking in case the tank settles Make swing joints so they will tighten as tank settles Non hardening pipe joint compounds should be used on all threads Do not use Teflon tape as an oil pipe sealant It can cause valves to fail creating hazards Do not use compression fittings only flare fittings e Underground pipe must be run in a casing to prevent oil leaking into ground or under floor Check local codes for information Oil piping connection at burner see FIGURE 15 for recommended connection at burner allowing burner mounting door to swing open completely for servicing 0119 025 Flare fitting Recommended Oil Piping Connection to Burner FIGURE 15 DANGER Follow information below to prevent severe personal injury death or substantial property damage Do not use gasoline crankcase drainings any oil containing gasoline See burner manual for proper fuel oil Do not attempt to start burner when excess oil has accumulated when unit is full of vapor or when combustion chamber is very hot Do not start burner unless collector hood flue cap jacket cap breeching and burner mounting door are secured in place Never burn garbage or paper in the boiler Never leave combustible material around it Fill the system 1 Do not fill except for leakage tests until boile
16. to desired adjustment made with combustion ore Ips Rue test equipment P 8 Test pressure control While burner is d 16 etn m operating move indicator on limit control LM below actual boiler steam pressure Burner DL Bsvieved should go off Raise setting on pressure with Omer control above steam pressure and burner person and instructed person to keep should re ignite for future reference 9 Test low water cutoff s Follow control 18 provided with manufacturer s instructions for testing procedures Make sure burner goes off when control responds to low water condition Burner should re ignite when proper water level is restored boiler to its envelope and placed with boiler for future reference Installation and Service Certificate Date Installed Installation instructions have been followed Boiler Model Number Series Check out procedure has been performed CP Number s Above information is certified to be correct L LLL Measured Btu or GPH Input Information received and left with owner maintenance person Installer Company Address Phone Installer s Signature Burner adjustments for and boilers Final burner adjustments must A WARNING made using combustion test equipment to assure proper operation Do not fire boiler without water or sections will overheat
17. TWO PIPE SYSTEMS BOILER MODEL NUMBER BOILER MODEL NUMBER HEADER PIPE EQUALIZER SIZE PIPE SIZE sp HEADER PIPE SIZE EQUALIZER PIPE SIZE Based ASHRAE Fundamentals Handbook recommendations allowing 1 2 oz pressure drop at 0 psig Based on ASHRAE Fundamentals Handbook recommendations allowing 2 oz pressure drop per 100 feet of pipe at 3 5 psig Maintain minimum 24 height from waterline to bottom of header Can be reduced to 2 Reducing elbow 2 n Optional reservoir piping See page 17 Close nipple Es 9 E lt T in i d A HL ig QUT Steam relief valve s discharge piping b 2 24 law Steam Piping for Sizes 3 through 5 See Page 16 for Sizes 6 through 9 FIGURE 9 _ Float type low water cutoff blowdown piping Optional reservoir piping See page 17 lt Close nipple Condensate returns P Steam relief valve discharge piping Float type gt low water cutoff PL blowdown piping 7 9345 Steam Piping for Sizes 6 through 9 See Page 15 for Sizes 3 through 5 FIGURE 10 Connect Steam Piping continued Optional reservoir piping To size and install reservoir piping see FIGURE 11 Modern steam boilers are designed to steam for and Bulletin AE 8403 available through your less time
18. al codes In Canada CSA C22 1 Canadian Electrical Code Part One and any local codes e Wiring must be N E C Class 1 If original wire as supplied with boiler must be replaced type 105 C wire or equivalent must be used Supply wiring to boiler and additional control wiring must be 14 ga or heavier e Provide electrical ground at boiler as required by codes Thermostat wiring Install thermostat on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sun rays or fireplaces e Follow instructions with thermostat If it has a heat anticipator set heat anticipator in thermostat to match power requirements of equipment connected to it Boiler wiring diagrams give setting for standard equipment To wire boilers refer to the following pages Junction box furnished Junction box houses electrical connections for all boiler components P boilers have harnesses furnished A boilers are furnished with burner and limit harnesses field provided high voltage wiring must be sheathed in flexible metal conduit Connect incoming line voltage HOT wire to service switch and neutral wire to white wire Field install equipment ground wire to green wire with wire nut service switch 15 amp is provided with boiler A boilers install switch as shown Some local codes may require an emergency shut off switch installed at a location away from boiler Follow local cod
19. commend the following precautions be taken when handling these materials Precautionary measures e Avoid breathing fiberglass dust and contact with skin and eyes e Use NIOSH approved dust mist respirator e Wear long sleeved loose fitting clothing gloves and eye protection e Wash work clothes separately from other clothing Rinse washer thoroughly e Operations such as sawing blowing tearout and spraying may generate airborne fiber concentration requiring additional protection First aid measures e Eye contact Flush eyes with water to remove dust If symptoms persist seek medical attention e Skin contact Wash affected areas gently with soap and warm water after handling Install Non Packaged Boiler CONTINUED Place boiler 1 Non Packaged SGO 3 through 6 position on site if TinN Smaller sized boilers may A CAUTION top heavy Use caution when handling to avoid minor personal injury or property damage a Boiler is shipped for back flue outlet To change to top flue outlet see FIGURE 3 1 Loosen two screws holding flue cap strap to collector hood Remove strap and flue cap from opening Re tighten screws 2 Check rope placement inside flue cap Read AWARNING under step 3 at right 3 Loosen two screws on back flue outlet set flue cap on outlet Install strap by engaging slots in screws Tighten screws Make sure cap is securely installed 2 Non Packaged SGO 7 8 amp 9
20. control oss i and cocks y lt T A Ji e l OS dain 0107025 Steam Boiler Controls With Probe Type LWCO Optional Tankless Heater Control FIGURE 6 Install Packaged and Non Packaged Boiler P General chimney requirements e Designed for natural draft firing Connect boiler to vertical chimney A DANGER Insufficient draft can cause flue gas leakage and carbon monoxide emissions which will lead to severe personal injury or death e Use vent material approved by local codes for oil fired burners In their absence refer to 31 Installation of Oil Burning Equipment NFPA211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances Canada refer to CSA B139 Installation Code for Oil Burning Equipment e NFPA 211 requires chimney to be lined before connected to boiler Inspect existing chimney before DANGER installing new boiler Failure to do any of the following will result in severe personal injury or death Clean chimney including removal of blockage Repair or replace damaged pipe or liner Repair mortar and joints To prevent downdrafts extend chimney at least 3 feet above highest point where it passes through roof and 2 feet higher than any portion of building within 10 feet Increase chimney cross sectional area and height at least 496 per 1 000 feet above sea level e Minimum cleara
21. d damage cast iron resulting in severe personal injury death or substantial property damage Check for maintained gauge pressure for more than 10 minutes Visually check for leaks if gauge pressure drops Drain boiler Repair leaks if found I Using petroleum based A CAUTION compounds to repair leaks can damage system components resulting in property damage Retest boiler after repairing leaks Remove pressure gauge air vent and plugs Re install steam pressure gauge pressure control and low water cutoff furnished with boiler Go to page 12 to connect breeching and venting Install Packaged Boiler CONTINUED Sealing rope inside groove Jacket is E insulation amp Flue cap Flue cap strap Jacket cap Change From Back Flue Outlet to Top Flue Outlet Optional FIGURE 2 Install Non Packaged Boiler Fiberglass wool and ceramic fiber materials POSSIBLE CANCER HAZARD A WARNING BY INHALATION CAN CAUSE RESPIRATORY SKIN AND EYE IRRITATION This product contains fiberglass wool and ceramic fiber materials Airborne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation Apply special care when handling ceramic fiber chamber lining and base insulation materials Ceramic fibers can be converted to chrystobalites a substance listed as a probable cause of cancer Suppliers of fiberglass wool products re
22. e building and nothing need be added for normal piping and pick up Steam ratings are based on a piping and pick up allowance of 1 33 additional allowance should be made for unusual piping and pick up loads Consult local Weil McLain Sales Office 6 I B R gross output 7 See page 12 for minimum breeching diameter 8 To water line 8 Listed draft losses are for factory shipped settings TM 8 Weil McLain 7m Mc LAIN sag pane Michigan City IN 46360 2388 http www weil mclain com
23. eeching and venting for proper operation For additional information refer to instructions packed with boiler or burner Burner Manual Maintenance and Service Guide for GOLD Oil Steam Boilers 25 Check off steps as completed 10 Test additional field installed controls If boiler has additional operating control or 1 Boiler properly filled with water other controls test for operation as o f f outlined by control manulacturer Burner L 2 Boiler piping checked for leaks including should be operating and should go off tankless heater if used when controls are tested When controls L 3 System vents operating properly are restored burner should re ignite L 4 Boiler properly skimmed 11 Limit control set to system pressure requirements M 5 pir pn CHOC RED 12 Thermostat heat anticipator setting if D I available set properly Refer to Connect L 6 Flue cap in place and tightened Burner wiring page 19 a i L 13 Boiler cycled with thermostat Raise to highest setting and verify boiler goes Obtain gas tight seal to through normal start up cycle Lower to prevent possible flue gas lowest setting and verify boiler goes off d M 14 Observed several operating cycles for leading to severe personal injury or death proper operation DES d7 ned L 15 Set room thermostat s
24. efore boiler operation Lay a foundation if needed Boiler may be installed on non carpeted combustible flooring For residential garage installation install boiler so burner is at least 18 inches above floor to avoid contact with gasoline fumes A level concrete or masonry foundation is required when e Floor could possibly become flooded e Non level conditions exist Solid concrete blocks can be used to create a pad BOILER FOUNDATION SIZE TABLE BOILER MODEL MIN HEIGHT INCHES LENGTH INCHES 17 WIDTH INCHES Go to page 6 to install boiler Go to page 7 to install boiler Install Packaged Boiler Place boiler Remove boiler from pallet TI Do not drop boiler or bump NOTICE jacket on floor or pallet Damage to boiler can result omaller sized boilers may be A CAUTION top heavy Use caution when handling to avoid minor personal injury or property damage Boiler is shipped for back flue outlet To change to top flue outlet see FIGURE 2 a Remove jacket cap on top of boiler b Loosen two screws holding flue cap strap to collector hood Remove strap and flue cap from opening Re tighten screws Check rope placement inside flue cap Read A WARNING under step 5 below gt d Loosen two screws on back flue outlet Set flue cap on outlet Install strap by engaging slots in screws Tighten screws Make sure cap is securely installed onap jacket cap in back outlet opening
25. es Burner wiring Burner harness incorporates a disconnect plug providing a convenient way to disconnect wiring when burner mounting door is opened P boilers have a power disconnect plug installed on burner On boilers mount the plug provided in steam trim carton on the burner housing as shown in FIGURE 13 or 14 For Carlin burners screw burner plug into threaded conduit coupling then mount this assembly to the burner housing using the chase nipple Route wires through housing and make connections in burner junction box as shown in boiler wiring diagram Pages 20 to 21 Float Type Pages 22 to 23 Probe Type LE WCO CONTINUED iring Connect W L0zL g 0V 09 H3HWN 1HVd pona 0 0 e gumas UM 191690 Ssa que noypi 10 WEDS e pur PI pur anm pea sey aapea prouajos purdi 6 AH por uy an gp pun AA pasopoo sarta x pea paryddns tu tudinb g Ww weeg 01 pinoi OI NIYI J pure qapas 30041295 ojos our j5ouuo paJlJ IO O70 ei qe 12 9 PY
26. g jeep 40 Anjuy asaos wea puezey 6944901 LE Md i SSHNHVH 2 SON i ad u A BSN fa HOLINEM eiim autos amps mal 4 Oa ap gt cp m AA t 7CIOHLNOO T my m Ll F m Float Type Low Water Cutoff D Pressure Control Wiring Harness 2 Tankless Heater Control Wiring 3 Burner Disconnect Plug 4 Burner Wiring Harness 5 Low Water Cutoff Wiring Harness not furnished on A Boilers Boiler Wiring for Float Type LWCO FIGURE 13 11 CONTINUED iring Connect W LOzL B BEDV 09 HJAWNN LHVd Mi Au ueta IS 006 vows NIMTPU TI Wil 1 Og 1 jjojn2 944 800 e 29129 Ssapque 1 10 WESS e OVS pur pur M 5205 pey set apog aapea prouaqpos susuudmbo 6 pue 4g pug pur Mo en TAIM pe sey qiia parddns sopua qusurdmbo Imur uc 02218 o adt 1320007 3304 A 221 RAIN LAS 200435 O
27. installation must comply with valve manufacturer s recommendations and instructions Water heated to a temperature suitable for clothes washing dish washing and other sanitizing needs will scald and cause injury Children and elderly infirm or physically handicapped persons are more likely to be injured by hot water Never leave them unattended in or near a bathtub shower or sink Never allow small children to use a hot water faucet or draw their own bath If anyone using hot water in the building fits this description or if state laws or local codes require certain water temperatures at hot water faucets take special precautions Install automatic mixing valve set according to those standards Use lowest practical temperature setting Check water temperature immediately after first heating cycle and after any adjustment AWARNING Studies have indicated that dangerous bacteria can form in potable water distribution systems if certain minimum water temperatures are not maintained Contact local health department for more information Flow Boiler water including additives is practically non toxic having toxicity rating or class of 1 as listed in Clinical Toxicology af Commercial Products Boiler water pressure is limited to max 15 psig by approved steam relief valve Supply To pipe tankless heater L 2 5603 5 Tankless Heater Control Location 5006 9 Tankless Regulating Valve Heater C
28. ls shipped separately When Calling or Writing About the Boiler Please have boiler model number and series from boiler rating label and CP number s from boiler jacket burner and controls On page 26 of this manual is space to list CP number s A WARNING Read all instructions before installing Failure to follow all instructions in proper order can cause severe personal injury death or substantial property damage Read This Page First 2 Table of Contents ates esters 3 Before Installing Boiler 4 5 Install Packaged Boiler 6 7 Install Non Packaged Boiler 7 11 Connect 12 13 Connect Steam Piping 14 17 Connect Tankless Heater Piping 18 Connect Wiring 19 23 Connect Piping 2 4 Start UD 433 934 199 99 194323 25 Check Out Procedure 26 Installation and Service Certificate 26 ADDpeDndIX 35355 4 9 27 Parts LISE 28 Parts Drawing Re eres nad 29 DIMENSIONS 22499 S 30 31 005 9 da oe Back Cover Before Installing Boiler Installations must comply with U S State and local plumbing heating and electrical codes
29. nces from vent pipe to combustible material 6 inches L doublewall vent 18 inches Singlewall vent e Minimum chimney sizes should be used NOTICE Oversized chimneys outside masonry chimneys and or derated inputs can result in condensation in chimney Connect breeching A WARNING Long horizontal breechings excessive number of tees and MINIMUM CHIMNEY SIZE TABLE seek MINIMUM BOILER MINIMUM I B R MINIMUM MODEL BREECHING CHIMNEY SIZE CHIMNEY NUMBER DIAMETER ROUND HEIGHT 6 x 634 inside liner 6 5 x 1044 inside liner Flue collar on boiler is 7 diameter elbows or other obstructions restricting combustion gas flow can result in possibility of condensation flue gas leakage and carbon monoxide emissions which can lead to severe personal injury or death 1 Install 2 flue pipe brackets 2 Connect full sized breeching when possible See Minimum Chimney Size Table Back outlet see FIGURE 7 Top outlet see FIGURE 8 3 Connection must be made above bottom of chimney to avoid blockage Breeching must not enter chimney far enough to cause obstruction Use thimble or slip joint where breeching enters chimney to allow removal for cleaning 4 When burner and boiler are properly installed draft overfire will be approximately 0 01 to 0 02 W C Install barometric control in breeching per control manufacturer s instructions when excess d
30. oiler between control and boiler Set control to minimum of 5 psi above setpoint of existing control and maximum setting of 15 psi Wire as shown on boiler wiring diagram Install piping l oee Tables at right and FIGURE 9 on page 15 or FIGURE 10 on page 16 CAUTION Improperly piped systems or undersized piping can contribute to erratic boiler operation and possible boiler or system damage Piping system must be installed as shown using minimum pipe sizes shown Consult your Weil McLain distributor or sales office before installing alternate piping Install relief valve vertically in tapping on back of boiler See FIGURE 9 or 10 and also refer to tag attached to relief valve for manufacturer s instructions unam Pipe relief valve discharge line AWARNING 7 16 vave discharge i near floor close to floor drain to eliminate potential of severe burns Do not pipe to any area where freezing could occur Do not plug valve or place any obstruction in discharge line 3 Float type low water cutoff only install blowdown line in bottom of cutoff See FIGURE 9 or 10 and also refer to low water cutoff manufacturer s instructions for details AW ARNING Pipe blowdown line near floor close to floor drain to eliminate potential of severe burns Do not pipe to any area where freezing could occur Do not plug valve or place any obstruction in discharge line STEAM PIPING SIZE TABLE FOR ONE AND
31. ontrol b Location Cold Water Tankless Heater Piping FIGURE 12 BOILER MODEL oize piping no smaller than tankless heater inlet and outlet Following controls furnished by others must be installed a Automatic mixing valve See FIGURE 12 Read at left b Flow regulating valve Size according to intermittent draw of tankless heater See Table below Follow valve manufacturer s instructions to install Additional anti scald devices may be installed at each hot water faucet bath and shower outlet In hard water areas soften cold domestic supply water to heaters to prevent lime build up TANKLESS HEATER RATINGS TABLE INTERMITTENT INLET HEATER DRAW RATINGS AND OUTLET To avoid supplying steam to system during summer tankless operation raise water level to one inch above normal water line Gallons of water per minute heated from 40 F to 140 F with 200 F boiler water temperature Tested in accordance with I W H Testing and Rating Standard for Indirect Tankless Water Heaters Tested with Boilers Automatic Mixing Valve General wiring requirements Arpa mn Electric shock hazard Can cause A WARNING severe personal injury or death if power source including service switch on boiler is not disconnected before installing or servicing Installations must follow these codes National Electrical Code ANSI NFPA 70 latest edition and any additional national state or loc
32. ping to observe skim water level Raise waterline to midpoint of skim tapping 2 Fire burner to maintain water temperature below steaming temperature during skimming process 3 Feed in water to maintain water level Cycle burner to prevent rise in steam pressure Continue skimming until discharge is clear 4 While boiler is warm but not hot drain boiler through drain valve 5 Remove skim piping Close drain valve Fill with fresh water to normal waterline Start burner and steam for 15 minutes to remove dissolved gases Stop burner 6 Check traps and air vents for proper operation 7 Process may need to be repeated after several weeks of operation To place in operation 1 Verify boiler is filled with water to normal waterline as indicated on jacket front panel 2 Open burner door and verify rear target wall floor and burner door insulations are in proper position and condition 3 Verify burner mounting door is closed tightly and burner wiring harness is connected to junction box 4 Factory burner adjustment and settings may not be suitable for specific job conditions See Appendix page 27 A WARNING Make final burner adjustments using combustion test equipment to assure proper operation Do not fire boiler without water Sections will overheat damaging boiler and resulting in substantial property damage 5 Check boiler and system piping for leaks see Tips for steam systems 6 Inspect br
33. r is ready to be fired 2 Fill to normal water line as indicated on jacket front panel 3 Boiler water 7 0 to 8 5 is recommended TIC F Failure to maintain recommended pH level can cause section failure and leaks 4 Follow Skim steam boiler to assure proper operation Tips for steam systems e Check boiler and system piping for leaks Continual makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer and causing cast iron to overheat resulting in section failure CAUTION Failure to maintain recommended pH and repair leaks can cause section iron corrosion leading to section failure and leaks Do not use petroleum based sealing or stop leak compounds in boiler system Damage to system components can result e For pH conditions outside 7 0 to 8 5 range or unusually hard water areas above 7 grains hardness consult local water treatment company Skim steam boiler NO TICE Clean new steam boilers to remove any impurities Failure to properly clean can result in violent water level fluctuations water passing into steam mains or high maintenance costs on strainers traps or vents okim boiler only Do not clean old piping or leaks can occur AIT 1 Do not use petroleum based A CAUTION compounds in boiler system Damage to system components can result causing property damage l Provide 1 skim piping from skim tapping to floor drain Add a tee in pi
34. raft needs to be relieved or to comply with applicable codes and regulations Use draft gauge to adjust proper opening 5 An induced draft fan for the chimney may be necessary if Excessive resistance to flow of combustion gases can be expected Cross sectional area of chimney is smaller than minimum recommended Chimney height is less than recommended Seal all vent joints Interlock burner with fan operation Connect Breeching CONTINUED Typical Location for Barometric Control Also see Control Manufacturer s Instructions Flue Pipe Bracket One on Each Side of Pipe Back Outlet Breeching Connection FIGURE 7 Typical Location for Barometric Control Also see Control Manufacturer s Fd Instructions Flue Pipe Bracket One on Each Side of Pipe Top Outlet Breeching Connection FIGURE 8 Connect Steam Piping General piping information Hartford Loop piping arrangement and wet return are required for steam boilers Maintain 24 inch minimum from waterline to bottom of header minimum 507 from floor or top of foundation When using condensate receiver feed pump must be energized by boiler mounted pump control Use swing joints in steam piping If installation is to comply with ASME or Canadian requirements an additional pressure limit control is needed Install control between existing pressure control and pressure gauge Control must be installed with siphon supplied with b
35. side jacket panel and for SGO 6 only remove tankless heater control knockout Remove tankless heater cover plate and gasket Install new gasket and tankless heater over studs around opening Secure with nuts Perform hydrostatic pressure test l Refer to FIGURE 4 and Control Tapping Table on page 10 to install a Boiler drain b Water pressure gauge test only Be sure gauge can handle test pressure c Air vent in tapping on top of boiler d Plugs in remaining tappings Fill boiler Vent all air Pressure test boiler at 45 55 psig Do not leave boiler unattended AWARNING Cold water fill could expand and damage cast iron resulting in severe personal injury death or substantial property damage Check for maintained gauge pressure for more than 10 minutes Visually check for leaks if gauge pressure drops Drain boiler Repair leaks if found Do not use petroleum based A CAUTION compounds to repair leaks Damage to system components can result causing property damage Sealing Rope in Groove Inside Cap Flue Cap Strap Change From Back Flue Outlet to Top Flue Outlet Optional FIGURE 3 Re test boiler after repairing leaks Remove pressure gauge air vent and plugs from tappings used for controls check sealing rope placement Metal to metal contact around port openings Flue collector hood seal Burner mounting door seal AW Obtain gas tight seal to prevent AWARNING
36. than older larger boilers When replacing Weil McLain distributor or sales office an older steam boiler the system condensate return time may be longer than the steaming time 1 Pipe boiler as shown on pages 14 through 16 This can cause the following problems 2 Use 8 diameter reservoir pipe e Boilers fitted with an automatic water feed 3 Locate centerline of reservoir pipe 1 below could overfill 26 boiler waterline Units fitted with only a low water cutoff would shut down and cycle while waiting for condensate to return CONDENSATE RECEIVER CAPACITY TABLE MINIMUM CONDENSATERECEIVERCAPACITY GAL RECOMMENDED I B R GROSS CONDENSATE OUTPUT GALLONS I5 MIN 30 MIN 45 MIN 60 MIN FEED PUMPING RATE BOILER LBS STEAM CONDENSATE BOILER BOILER BOILER BOILER GPM PER HOUR PER HOUR OPERATION OPERATION OPERATION OPERATION AT 15 PSI Maximum time to when condensate returns to boiler Bero at header 4 Reservoir 25678 PP Water line D115 075 Typical Piping One Riser Shown on Boiler FIGURE 11 Connect Tankless Heater Piping DANGER Hot Water Can Scald These single wall heat exchangers comply with National Standard Plumbing Code provided that Consumer Product Safety Commission and some states recommend domestic hot water temperature of 130 F or less When installing an automatic mixing valve selection and
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