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Weil-McLain 88 manual

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Table of contents for the manual

  • Page 1

    P art No . 550-100-068/0308 fo r use w i th Ga s, Li gh t O il, & Ga s / Lig h t Oi l – Fir ed Bu rn er s This man ual must only be used by a qualified heating installer/ser vice technician. Read all instructions before installing. Follo w al l in- structions in proper orde r . Fail ure to comply could result in se ver e p ersonal injur y , [...]

  • Page 2

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 2 P art No . 550-100-068/0308 Hazard Definitions The following defined terms are used throughout this manual to bring attention to the pr esence of hazards of various risk levels, o r to important information c oncern- ing the life of t[...]

  • Page 3

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 3 P art No . 550-100-068/0308                        4 ?[...]

  • Page 4

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 4 P art No . 550-100-068/0308 Installation must comply with — State, pr ovincial and lo cal plumbing, heating and electr ical 1 . codes. Regulations of ser vicing utilities. 2. ASME Section IV , L ow Pr essure Boiler and P ressur e V es[...]

  • Page 5

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 5 P art No . 550-100-068/0308 Before installing boiler (continued) Combustion and ventilation air openings A dequate combustion and ventilation air must be pro vided to assure pr oper c ombustion and p revent possibility of ue gas leakage and carbon mono xide emissions, causi[...]

  • Page 6

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 6 P art No . 550-100-068/0308 freely co mmunicate with the outdoors, as follows: W here directly co mmunicating with the outdoors or where • communicating to the outdoors through vertical ducts, ea ch opening shall hav e a minimum fr[...]

  • Page 7

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 7 P art No . 550-100-068/0308 Set boiler in place Section assemb ly lifting weights         (pounds) ?[...]

  • Page 8

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 8 P art No . 550-100-068/0308 Assembling the block Sections are top heavy . U nbolted sect ions may fall if not suppor ted, resulting in se ver e personal injur y or death. Prepar e and position back section Apply 1. 1 / 8 " contin u[...]

  • Page 9

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 9 P art No . 550-100-068/0308 Sections are top heavy . U nbolted sect ions may fall if not suppor ted, resulting in se ver e personal injur y or death. Install intermediate sections Re move and discar d 1. 3 / 8 " diameter shipping tie rods. Re move grit from port machined [...]

  • Page 10

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 10 P art No . 550-100-068/0308 Assembling the block (continued) Section arr angement    W = water S = steam     [...]

  • Page 11

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 11 P art No . 550-100-068/0308 P erform hydrostatic pressure test Prepar e boiler and test: See 1. Figure 10 and Figure 11 f or tapping locations. Install: Boiler drain (not furnished). a. W ater pressure g auge — for test only . Be sure gauge can handle b. test press ure — [...]

  • Page 12

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 12 P art No . 550-100-068/0308 Inser t HXT -bars through cleanout openings as shown below (omit the bottom, b lue-tipped, HXT -bar in the opening  between the front section and the first intermediate section) C[...]

  • Page 13

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 13 P art No . 550-100-068/0308 Cleanout plate assembly  Complete block assembly (continued) Th e b oi le r co nt ai ns cer a mi c fi be r a nd fiberglass materials. U se care when han- dling these mat erials per instructions on page 34 of this manual[...]

  • Page 14

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 14 P art No . 550-100-068/0308 Connect water boiler piping General water piping information Syst em water supply and return piping should b e installe d and 1. piping connecti ons attached to boiler before erecting jacket or installing co[...]

  • Page 15

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 15 P art No . 550-100-068/0308 Connect water boiler piping (continued) Recommended minimum pipe sizes when flo w rate is  not known (see Figure 14, page page 14) (note 1)   [...]

  • Page 16

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 16 P art No . 550-100-068/0308 Connect steam boiler piping General steam piping information: Hartford loop piping arrangement and wet return ar e requir ed for 1. steam boilers. Use the Hartford loop for both pumped-return and gravit y-re[...]

  • Page 17

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 17 P art No . 550-100-068/0308 Connect steam boiler piping (continued) Model 488 through 688 steam (1 riser)  Model 788 through 1188 steam (2 risers required)  Imp rop e rl y pi pe d s ys tem s or u nd er si ze d pi p in g c [...]

  • Page 18

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 18 P art No . 550-100-068/0308 Connect steam boiler piping (continued) Model 1288 through 1888 steam (3 or 4 risers required)  Drawing legend & notes (Figure 23 through Figure 26) Riser pipes (one for each s[...]

  • Page 19

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 19 P art No . 550-100-068/0308 Multiple Steam Boiler Piping Gra vity Condensate Retur n  Connect steam boiler piping (continued) Pipe as shown for gravit y r eturn systems, connect- A ing point A to the wet gravity return. Fo r pumpe d-re turn sys tem [...]

  • Page 20

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 20 P art No . 550-100-068/0308 Install jack et Before installing jacket The boiler contains ceramic fiber and fiberglass materials. U se care when hand ling these materials per instructions on page 34 of this manual. Fail ure to co mply[...]

  • Page 21

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 21 P art No . 550-100-068/0308 Installing jack et suppor t brack ets, support channels and cor ners  (piping and other components omitted for clarity) Install jack et (continued)[...]

  • Page 22

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 22 P art No . 550-100-068/0308 Installing (removing) jac ket front, rear  and side panels Press jack et trim down ov er jack et front,  rear and side panels Install jack et (continued)[...]

  • Page 23

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 23 P art No . 550-100-068/0308 Jac ket side panel placement  Install jack et (continued)[...]

  • Page 24

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 24 P art No . 550-100-068/0308 Jac ket top panel placement  Install jack et (continued)[...]

  • Page 25

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 25 P art No . 550-100-068/0308  Cons umer Pr oduct Saf ety Comm issio n and som e states recommend domestic hot water tempera- ture of 130°F or less. When installing an automatic mixing valve, se- lection and installat[...]

  • Page 26

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 26 P art No . 550-100-068/0308 Install water boiler controls Install controls: Install furnished controls per 1. Figure 36 and Figure 37. Failur e to properly install, pipe and wire boiler controls can result in severe damage to boiler , [...]

  • Page 27

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 27 P art No . 550-100-068/0308 Install steam boiler controls Install controls: Install contr ols where shown in 1. Figure 38 and Figure 39. Failur e to properly install, pipe and wire boile r contr ols can result in severe damage to boiler , building and per- sonnel; and is not [...]

  • Page 28

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 28 P art No . 550-100-068/0308 Install steam boiler controls (continued) Steam control siphon and fittings  Float-type water le v el control locations  ?[...]

  • Page 29

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 29 P art No . 550-100-068/0308 Connect breeching and venting systems General venting information M odel 88 boilers operate w ith positive overfire pressure. Adj ust 1. damper assembly (see Figure 49, page 33) during burner start-up to achieve 0.1" W .C. positiv e pressur e[...]

  • Page 30

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 30 P art No . 550-100-068/0308 Connect breeching and venting systems Stub vent – f orced draft — single boiler  Conv entional chimney – balanced dr aft  with barometr ic draft co[...]

  • Page 31

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 31 P art No . 550-100-068/0308 Install burner & wiring and fill system T o install bur ner U npack burner . 1. Place gasket around air tube and against burner mounting ange. 2. If sealing rope is used, apply 1 / 8 " co ntinuous bead of rope adhesive around burner mo[...]

  • Page 32

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 32 P art No . 550-100-068/0308 Install fuel piping Gas piping In sizing the gas piping , the following fac tors should be consid- 1. ered: Diameter and length of the gas supply piping . a. N umber of fittings. b. Maximum gas consumption [...]

  • Page 33

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 33 P art No . 550-100-068/0308 Mak e final adjustments Flue collar/damper assembly  Adjust burner and damper assembly: Lock ue damper OPEN ( 1. Figure 49). Mak e final burner adjustments using combustion test equipme nt to assure pr oper operation[...]

  • Page 34

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 34 P art No . 550-100-068/0308 Handling ceramic fiber and fiberglass materials REMOV AL OF FRONT PLA TE OR CLEANOUT PLA TE MA TERIALS The burner fr ont plate and cleanou t plate gask ets contain ceramic fiber mate rials. Ceramic fiber[...]

  • Page 35

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 35 P art No . 550-100-068/0308 Ratings Boiler model number I=B=R burner capacity Gross I=B=R output Net I=B=R ratings Boiler H.P . Combustion efficiency Thermal efficiency Net firebox volume Flue gas volume P ositive pressure in firebox Flue outlet diameter Boiler water cont[...]

  • Page 36

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 36 P art No . 550-100-068/0308 Dimensions Dimensions (inches) Model A B C D E L W H 488 23 — — 10 54 ¾ 34 ¾ 30 23 C, 588 31 — — 10 54 ¾ 42 ¾ 38 31 C, 688 39 — — 10 54 ¾ 50 ¾ 46 39 C, 788 47 — — 12 53 ¾ 58 ¾ 54 4[...]

  • Page 37

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 37 P art No . 550-100-068/0308 Dimensions (continued) Dimensions (see lettered dimensions on opposite page) [...]

  • Page 38

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 38 P art No . 550-100-068/0308 P arts Item Description Part number 1 F ront sections (8823) 316-301-210 2 Regular intermediate section (8825) 316-301-212 3 T ankless intermediate section (8826) 316-301-214 4 Back section (8828) 316-301-21[...]

  • Page 39

    Boiler manual: • Installation • Start-Up • Maintenance • Parts 39 P art No . 550-100-068/0308 P arts (continued) P ar ts [...]

  • Page 40

    W eil-McLain 88 W ater and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners 40 P art No . 550-100-068/0308 W arranty R esi d e nt i a l & Co mme rcia l C a st Ir on B o il er s  R e sid e ntial W a te r W a rran ty — Lim ite d L i fe tim e  R e sid e nt ia l S t e am W a rr ant y — Li m ite d 10 Y e[...]