Weil-mclain boiler installation instructions

Steam boilers — Do not substitute another manual reset low water cutoff for the one specified and supplied with the boiler. Other controls may not operate as intended and could cause serious operating problems or failures.

Welcome to ManualMachine. We have sent a verification link to to complete your registration. Log In Sign Up. Forgot password? Enter your email address and check your inbox. Please check your email for further instructions. Enter a new password. Hazard definitions To the installer:. Please read this page first The following terms are used throughout this Control Supplement to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

Contents I. Final adjustments Check-out procedure Service and maintenance Replacement parts CSD-1 control system — Natural gas Install optional vent damper if supplied. Keep wiring harnesses clear of all hot surfaces. Keyway Key Read and apply the harness plug warning label above so that it is visible after installation. Effikal damper Johnson Controls damper Figure 2 Vent damper assemblies Damper blade indicator Hold-open switch Effikal only — Install damper so that switch is visible and accessible to user.

VI Wiring For your safety, turn off electrical power supply before making any electrical connections to avoid possible shock hazard. Assembly illustrations and wiring diagrams This Supplement contains three wiring diagrams and associated assembly illustrations.

Wiring procedure 1. Connect these wires as shown in the wiring diagram. PILOT 4. You can only view or download manuals with. Sign Up and get 5 for free. Upload your files to the site. You get 1 for each file you add. Get 1 for every time someone downloads your manual. Buy as many as you need. View and download manuals available only for. Register and get 5 for free. Upload manuals that we do not have and get 1 for each file.

Get 1 for every download of your manual. Buy as much as you need. Steam, CSD-1, gravity return — or —. Note a — CSD-1 water boilers cannot be equipped with a tankless heater. Brass cross, brass nipple, bushings 3 and.

Brass cross, brass nipple, bushings 3. The controls may be mounted on either end of the boiler. Mount all controls. The junction box electrical entrance must also be mounted.

Install the probe low water cutoff in the supply or return piping, above the. The low water cutoff must be mounted between the boiler. Install a blowdown valve on any float type low water cutoff as described in. Drain connection per EGH manual. Skim tapping per EGH manual. Water boiler wiring —. Electrode probe-type is at the same point as the expansion tank connection to recommended. Purchase and install in tee in supply piping above boiler.

Eventual section failure can result. Diaphragm-type or bladder- Closed-type expansion tank type expansion tank Figure 9 Figure 10 1.

Ensure expansion tank size will handle boiler and 1. Ensure expansion tank size will handle boiler and system water volume and temperature.

See tank system water volume and temperature. Pitch any Also refer to Piping for systems radiant heating systems or converted gravity sys- tems, below, if applicable. If this gauge is not available however, adjust the It would allow This can cause increased heat from radiators tem-bypass because part of the circulator flow bypasses at the beginning of the system and reduced heat from the system through valve. This bypassed hot water radiators near the end of the system. Remove jacket front panel and refer to to pipe gas to boil- Table 4 1.

Refer to for pipe length and diameter. Base on rated boiler input divide by 1, to obtain cubic Install drip leg at inlet of gas connection to boiler. Where local Table 4 specific feet per hour. Connect thermostat as shown on wiring diagram Failure to do so can cause severe personal injury or on boiler. Severe damage to boiler floor and around the boiler for gas will occur, resulting in substantial property damage.

Do not proceed with start-up if there is Eliminate all system leaks. Continual fresh makeup any indication of a gas leak. Close manual and automatic and boiler drain cock. If found, repair Fill to correct system pressure. Correct pressure will vary with each immediately. Repeat this inspection after the boiler has application. Typical cold water fill pressure for a residential system is been started and the system has heated up.

Leaks must be repaired at once. Failure to do so could result in severe personal injury, death or substantial property damage. Section 8 or 9 to start the boiler.

Remove boiler Continual fresh makeup water jacket door and note the gas valve manufacturer will reduce boiler life. Blue flame. Inner cone engulfing thermocouple standing pilot or pilot flame sensor spark-ignited pilot. Thermocouple or pilot flame sensor glowing cherry red. Piping checked for leaks? Field wiring Burners re- ing instructions when operating the boiler. Failure to main ignited until thermostat circuit or limit circuit do so could result in severe personal injury, death or opens.

Burners and circulator are de-energized when substantial property damage. Burners are de-energized, but circulator remains on, if the limit circuit opens. Standby mode: After pilot is manually lit, the gas valve provides pilot Limit operation: When a limit control opens, the gas and maintains pilot as long as the thermocouple is satisfied. If ther- main gas valve is de-energized, but circulator con- mocouple signal drops for any reason, pilot must be manually lighted, tinues to run.

When the limit circuit closes again, Lighting Instructions following the in this manual and on boiler. Failure to do so a. Control module monitors pilot flame could result in severe personal injury, death or substantial current. If signal is lost, main valve closes, property damage. No gas flows to pilot or main gas valve. If power is interrupted, control system Call for heat Failure to perform the service and maintenance If any of these are present in the boiler intake air vicinity, they must be removed.

If they The boiler should be inspected and started annu- cannot be removed, install combustion air piping ally only , at the beginning of the heating season, to the boiler in accordance with national, provincial by a qualified service technician. In addition, the Position collector hood transition on back of boiler rear section, aligning collector hood transition flange holes with tapped holes in boiler rear section.

Install six remaining bolts securing collector hood transition to rear section. Finger-tighten only. Place collector hood assembly on sections:. Carefully set collector hood assembly on top of section assembly. Align slotted holes in collector hood flanges with the hold-down bolts in the sections. Place the collector hood assembly so its rear flange is against the collector hood transition flange gasket.

Thread flanged nuts onto hold-down bolts and fingertighten only. Thread on nuts and finger-tighten only. Tighten flue collector bolts and nuts:. Gradually tighten all bolts and nuts on flue collector assembly and boiler.

Alternate locations as you tighten the fasteners to ensure all parts are evenly drawn down, with no gaps or distortion of parts.

Install damper and flue caps:. Wipe item 5, Figure 10, flue damper flange surface with a clean rag. Apply a few pieces of double-faced tape to the flue damper flange. Position flue collar gasket on damper and press firmly in place. Align all holes before securing.

Position flue damper assembly against collector hood transition. Lightly tighten to hold flue damper in position. Insert remaining 10 screws into flue damper flange and lightly tighten. Alternate from screw to screw and tighten all screws evenly and securely. Install flue caps on flue collector top opening s using steps 5a through 5d.

DO NOT overtighten bolts in flue collector hood assembly. Gasket material could extrude, causing possible flue gas leakage and carbon monoxide emissions, resulting in severe personal injury or death. Place rear flue cap on rear section:. Wipe item 9, Figure 10, rear flue cap gasket surface with a clean rag. Apply a few pieces of double-faced tape on the rear flue cap gasket surface. Place the rectangular gasket item 8, Figure 10 on the flue cap, aligning holes in gasket with holes in rear flue cap.

Press firmly in place. Position rear flue cap on back of boiler rear section, aligning rear flue cap holes with tapped holes in boiler rear section. Install six remaining bolts securing rear flue cap to rear section. Fingertighten only. Place the collector hood assembly so its rear flange is against the rear flue cap gasket. Thread flanged nuts onto hold-down bolts and finger-tighten only. Install damper and flue caps see Figure 11, page 13 :.

Wipe item 5, Figure 10, flue damper flange surface and flue collector assembly surfaces with a clean rag. Position round gasket item 7, Figure 10 on flue collector assembly in the flue location shown in Figure 11, page Place flue damper assembly on gasket. Model top flue applications — always mount the damper assembly with the damper adjustment plate pointed toward the rear of the boiler as shown in Figure Otherwise, the jacket top panels may be difficult to install.

Install flue cap on remaining top opening if any using steps a through c, above. Open flue damper. Visually inspect inside section assembly and flue collector assembly for any light passing through unsealed areas. Check unsealed areas for cause — damaged gaskets, sealing rope not in place, or loose bolts or nuts. Correct all conditions and repeat inspection procedure. If unsealed areas cannot be eliminated, discontinue the boiler installation.

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Log In Sign Up. Forgot password? Enter your email address and check your inbox. Please check your email for further instructions. Enter a new password. ULTRA Before selecting boiler location 1. Check for nearby connections to: a.

Fuel supply b. Electrical power c. System water or steam piping d. Venting systems - see page 31 e. Lay a foundation, if needed: Floor construction and condition must be suitable for weight of boiler when filled with water. A level concrete or brick foundation constructed per Table 1 and Figure 1 is required when: 1. Non-level conditions exist. Table 1 Boiler foundation see Figure 3 Figure 1 Boiler foundation. Boiler top — 24 inches. Boiler front — 48 inches. Boiler flue — 9 inches. Boiler rear — 9 inches.

Boiler sides — 6 inches. Part No. Provide combustion and ventilation air openings: Do not install an exhaust fan in boiler room.

When all air is taken from outdoors, each opening should connect directly or by ducts from outdoors or crawl or attic spaces that freely connect with outdoors and sized as listed below: a.

Figure 2 Combustion and ventilation air openings — Boiler room below grade Figure 3 Combustion and ventilation air openings — Boiler room partially or completely above grade. Cut off cables. Mark all unsealed areas. Table 2 Lifting weights. For block assembly: 1. Use pipe rollers under steel skid angles to roll boiler. Install back refractory blanket 1. Apply adhesive to blanket. Prepare back section 1. Install intermediate sections Sections are top heavy.

Draw sections together until metal-to-metal contact is made around machined port openings see Figure 6 : a. After erecting first intermediate section, check both sections for plumb. Failure to plumb sections can cause misaligned piping and breeching, possibly resulting in property damage.

Install bottom refractory blanket on combustion chamber floor inside section block 1. Figure 6 Sealing ring installation and port alignment Table 3 Section arrangement Do not use petroleum-based cleaning or sealing compounds in boiler system. Prepare remaining sections 1. Install tankless heaters and gaskets or heater cover plates a. The flue outlet for top flue models must be located as shown in this manual. Install collector hold-down bolts 1. Prepare flue collector hood assembly Make sure gaskets are intact, not torn or otherwise damaged.

Figure 8 Collector hood preparation. For - a. Lay gasket on flange. See Figure 9: a. Figure 9 Flue collector sealing rope installation 10 Part No. Before installing flue collector 1. Rear flue boilers only: 1. Place collector hood transition on rear section: a. Place collector hood assembly on sections: a. Tighten flue collector bolts and nuts: a. Install damper and flue caps: a.

Top flue boilers only: 1. Place rear flue cap on rear section: a. Install damper and flue caps see Figure 11, page 13 : a. Check for gas-tight seal of all flue collector hood components.

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