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Weil-McLain 80 manual

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  • Page 1

    P art N o. 550-141-935/0602 Boiler Manual 80 W ater & steam boilers for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners This manual must only be used by a qualified heat ing installer/serv ice technician. R ead all inst ructions before installing. Follo w al l instructions in pro per orde r . Failu re to co mply could r esult in [...]

  • Page 2

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 2 P art No . 550-141-935/0602 Hazar d Definitions The following defined terms are used thr oughout this manual to bring attention t o the presenc e of hazards of various risk levels, or to important information conc erning the life of the product. Indicates p resenc e of hazard[...]

  • Page 3

    • Installation • Start-Up • Maintenance • Parts 3 P art No . 550-141-935/0602 Installation must compl y with — • State, pr ov incial and local plumbing, heating and electr ical codes. • R egulations of serv icing utilities. • N ational codes where applicable. Before selecting boiler location 1. Check fo r nearby co nnections to: a. [...]

  • Page 4

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 4 P art No . 550-141-935/0602 Befor e installing boiler (continued) 1 Figure 2 Combustion and v entilation air openings — Boiler room below grade Figure 3 Combustion and v entilation air openings — Boiler room par tially or completely abov e grade Pro vide combustion and ve[...]

  • Page 5

    • Installation • Start-Up • Maintenance • Parts 5 P art No . 550-141-935/0602 Set boiler in place 2 For packa ged boiler: 1. Remo ve top jack et panels. Set aside until after boiler is piped. The boiler contains ceramic fiber and fiberglass materials. U se care when handling these materials per instruc tions on page 38 o f this manual. Fail[...]

  • Page 6

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 6 P art No . 550-141-935/0602 Assemble block 3 Sections are top heavy . U nbolted sections ma y fall if not supported, r esulting in seve re personal inj ury or death. Install bac k refractory blanket 1. Lay back section o n floor with ports face up. 2. Appl y adhesiv e to blan[...]

  • Page 7

    • Installation • Start-Up • Maintenance • Parts 7 P art No . 550-141-935/0602 Install intermediate sections Sections are top hea vy . U nbolted sections may fall if not supported, resulting in se ve re personal injury or death. 1. R emove and discar d 3 / 8 " diameter shipping tie r ods. 2. R emove grit from port machined surfaces with[...]

  • Page 8

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 8 P art No . 550-141-935/0602 Perform hydr ostatic pr essur e test Prepare boiler and test: 1. See pages 28 and 29 for tapping locations. I nstall: a. Boiler drain (not furnished). b . W ater press ure gauge — for test only . Be sur e gauge can handle test pressure — see st[...]

  • Page 9

    • Installation • Start-Up • Maintenance • Parts 9 P art No . 550-141-935/0602 Install burner mounting plate on fr ont section 1. Install four ½" x 4¾" studs to secure burner mounting plate to section: a. Thread and lock together two nuts on r ounded end of stud. Thr ead flat end of stud into one of four holes lo cated around ope[...]

  • Page 10

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 10 P art No . 550-141-935/0602 Install flue collector 6 Figure 8 Collector hood preparation Figure 9 Flue collector sealing rope installation Flue collector assembl y 1. Figure 10, pag e 11, shows fl ue collector compo nents and locations. Figure 11, page 13, shows collector ho[...]

  • Page 11

    • Installation • Start-Up • Maintenance • Parts 11 P art No . 550-141-935/0602 Install flue collector (continued) 6 Figure 10 Flue collector components, typical (Model 880 collector configurations sho wn)[...]

  • Page 12

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 12 P art No . 550-141-935/0602 Install flue collector (continued) 6 Before installing flue collector 1. See Figure 10, page 11, for general assembly of flue collector c omponents. 2. See Figure 11, page 13 fo r the placement o f flue collec tor hoods on each model. 3. Pr epare [...]

  • Page 13

    • Installation • Start-Up • Maintenance • Parts 13 P art No . 550-141-935/0602 Figure 11 Flue collector components by model (see Figure 10, page 11 f or flue collector components not shown below) 6 Install flue collector (continued)[...]

  • Page 14

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 14 P art No . 550-141-935/0602 Connect water boiler piping 7 General water piping information: • Syst em wat er supply and r eturn piping should b e installed and piping connections attach ed to boiler befor e erecting jacket or installing co ntrols. • Do not pipe in throug[...]

  • Page 15

    • Installation • Start-Up • Maintenance • Parts 15 P art No . 550-141-935/0602 Connect water boiler piping (continued) 7 3. Piping for multiple boilers (see Figure 13): A Size seco ndar y boiler pump GPM based on following form ulas: Calculat e only secondary piping circuit resistanc e. Boiler resistance will be about equal to three 90 degr[...]

  • Page 16

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 16 P art No . 550-141-935/0602 Connect steam boiler piping 8 General steam piping information: • Hartfor d loop piping arrangement and wet return are required fo r steam boile rs. U se the Hartford loo p for both pumped-return and gr avity-ret urn systems. • Maintain 24-inc[...]

  • Page 17

    • Installation • Start-Up • Maintenance • Parts 17 P art No . 550-141-935/0602 Connect steam boiler piping (continued) 8 Figure 15 Model 380 through 580 steam boiler piping — NO TE minimum 24 inches betw een boiler water line and bottom of header . Figure 16 Model 680 through 980 steam boiler piping — NO TE minimum 24 inches between boi[...]

  • Page 18

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 18 P art No . 550-141-935/0602 T able 9 Condensate receiv er capacity Figure 18 Condensate piping to boiler Connect steam boiler piping (continued) 8 Figure 17 Model 1080 through 1280 steam boiler piping — NO TE minimum 24 inches between boiler w ater line and bottom of heade[...]

  • Page 19

    • Installation • Start-Up • Maintenance • Parts 19 P art No . 550-141-935/0602 Figure 19 Multiple Steam Boiler Piping Gravity Condensate Return Connect steam boiler piping (continued) 8 A Pipe as shown for gr avity return systems, c onnecting point A t o the wet gravity return. For pumped-return syst ems, install boiler water lev el control[...]

  • Page 20

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 20 P art No . 550-141-935/0602 Install jacket 9 Before installing jac ket 1. P ackaged boile rs • Install top jack et panels per instruc tions in this manual. 2. N on-packaged boilers • Follow the instructions in this section to install all jacket panels. • Make sure the [...]

  • Page 21

    • Installation • Start-Up • Maintenance • Parts 21 P art No . 550-141-935/0602 Figure 20 Installing jack et suppor t brack ets and rails and jac ket front and rear panels Install jacket (continued) 9[...]

  • Page 22

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 22 P art No . 550-141-935/0602 Figure 21 Installing (removing) jack et side panels and top panels Install jacket (continued) 9 Install jacket side panels 1. Re move jack et side panels from cartons. 2. Insert a plastic plug (pr ovided in jacket cartons) in the 1-inch hole in th[...]

  • Page 23

    • Installation • Start-Up • Maintenance • Parts 23 P art No . 550-141-935/0602 Figure 22 Jac ket side panel placement — Models 380, 480, 580 and 680 Install jacket (continued) 9[...]

  • Page 24

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 24 P art No . 550-141-935/0602 Figure 23 Jac ket side panel placement — Models 780, 880 and 980 Install jacket (continued) 9[...]

  • Page 25

    • Installation • Start-Up • Maintenance • Parts 25 P art No . 550-141-935/0602 Figure 24 Jac k et side panel placement — Models 1080, 1180, and 1280 Install jacket (continued) 9[...]

  • Page 26

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 26 P art No . 550-141-935/0602 Figure 25 J ack et top panel placement Install jacket (continued) 9[...]

  • Page 27

    • Installation • Start-Up • Maintenance • Parts 27 P art No . 550-141-935/0602 T o pipe tankless heaters: 1. Size piping no smaller than heater inlet and outlet. 2. A uto matic mixing valve must be installed. See Figure 26. Follow manufact urer’ s instr uctions to install. 3. Flow r egulating valve must be installed. Size ac cor ding to c[...]

  • Page 28

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 28 P art No . 550-141-935/0602 Install water boiler controls Install controls: 1. Install furnished co ntrols wher e shown in T able 11 and Figure 27. Failure t o pro perly install, pipe and wire boiler controls can r esult in severe damage to boiler , building and perso nnel; [...]

  • Page 29

    • Installation • Start-Up • Maintenance • Parts 29 P art No . 550-141-935/0602 Install steam boiler controls 12 Install controls: 1. Install controls whe re shown in T able 12 and Figure 28. Failure t o pr operly install, pipe and wire boiler c ontrols can r esult in severe damage to boiler , building and personnel; and is not cov ered by b[...]

  • Page 30

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 30 P art No . 550-141-935/0602 Install steam boiler contr ols (continued) 12 Figure 29 Steam control siphon and fittings T able 13 W ater le vel control locations Figure 30 W ater lev el control locations (see T able 13)[...]

  • Page 31

    • Installation • Start-Up • Maintenance • Parts 31 P art No . 550-141-935/0602 13 Connect br eeching and venting systems Figure 31 Stub vent – f orced draft — single boiler Figure 33 Conv entional chimney – balanced draft with barometric draft control when required — single boiler Figure 32 Stub vent – f orced draft — multiple b[...]

  • Page 32

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 32 P art No . 550-141-935/0602 Install bur ner 14 Wiring and fuel piping Make final adjustments 16 15 T o install burner: 1. U npack b urner . 2. Place gasket around air tube and against burner mounting flange. If sealing rope is used, apply 1 / 8 " continuous bead of rope[...]

  • Page 33

    • Installation • Start-Up • Maintenance • Parts 33 P art No . 550-141-935/0602 Make final adjustments (continued) 16 Figure 35 Flue damper assembly , typical Skim steam boilers: Clean all newly installed steam boilers to remov e oil. F ailure t o pro perly clean can result in violent water level fluctuations, water passing into steam mains,[...]

  • Page 34

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 34 P art No . 550-141-935/0602 Dimensions and ratings 17 Notes 1. Burner input based on maximum of 2,000 feet altitude. For higher altitudes consult local Weil-McLain representative. 2. No. 2 fuel oil Commercial Standard Spec. CS75-56. Heat value of oil — 140,000 Btu/Gal. 3. [...]

  • Page 35

    • Installation • Start-Up • Maintenance • Parts 35 P art No . 550-141-935/0602 17 Dimensions and ratings (continued)[...]

  • Page 36

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 36 P art No . 550-141-935/0602 18 Parts[...]

  • Page 37

    • Installation • Start-Up • Maintenance • Parts 37 P art No . 550-141-935/0602 18 Parts (continued)[...]

  • Page 38

    W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 38 P art No . 550-141-935/0602 Handling ceramic fiber and fiberglass materials REMO V AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The combustion chambe r lining or base insulation panels in this product contain c eramic fiber materials. C eramic fibers can be co nv e rted t[...]

  • Page 39

    • Installation • Start-Up • Maintenance • Parts 39 P art No . 550-141-935/0602 P ropane boilers — propane gas odorant Pr opane boilers o nly — Y our pr opane supplier mix es an odorant w ith the pro pane to make its prese nce detectable. In some instances, the odor ant can fade and the gas may no longer ha ve an odor . ■ Propane gas c[...]

  • Page 40

    W eil-McLain Limited W arranty f or Residential & Commercial Cast Iron Boilers ◆ ◆ ◆ ◆ ◆ RESIDENTIAL W A TER W ARRANTY—Limited Lifetime ◆ ◆ ◆ ◆ ◆ RESIDENTIAL STEAM W ARRANTY—Limited 10 Y ear ◆ ◆ ◆ ◆ ◆ COMMERCIAL W ARRANTY—Limited 10-Y ear N OT E : The residential steam and water warr anties do not cov er resi[...]