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Weil-McLain 88 Boiler User Manual

1. to prevent possibility of ue gas leakage and carbon monoxide emissions causing severe personal injury or death Cut rope as each section is completed 3 Remove any grit from port machined surfaces with clean rag AWARNING Do not use petroleum based cleaning or sealing com pounds in boiler system Severe damage to system components can result causing substantial property damage Place 9 and 6 sealing rings in appropriate port openings See Figure 6 If sealing ring slips out of groove stretch ring gently for several seconds then reposition in groove Apply continuous bead of silicone sealant no larger than 16 around entire outside edge of outer machined surface of port Refer to Figure 7 Do not apply silicone sealant on next to or under sealing ring AWARNING Silicone sealant applied as specified above prevents un burned oil vapors from coming in contact with sealing ring Vapor contact can damage rings resulting in severe damage to boiler and substantial property damage Hoist back section upright Then temporarily screw a 6 inch threaded pipe at least 36 inches long into the lower return tap ping Hoist the section and put into position Place a block under the 6 inch pipe to hold the back section up right and plumb ACAUTION The back section must be plumb before installing other sections to ensure the block will assemble correctly 9 The 6 inch support pipe and block can be removed after several
2. 3 Use oil filter sized for fuel pump suction gear capacity Install oil filter ACAUTION Do not install filter outside or close to an outside wall 5 Use continuous copper tubing to reduce possible piping leaks and to ensure reliable seal when oil piping is buried 6 Use are fittings not compression fittings Fire hazard DO NOT USE soldered fittings No safe A DANGER repair can be made 22 Figure 48 Gas supply piping 10 11 12 13 14 15 lt Manual main shul off gas valve when required TUI lt Ground joint union when required d To bumer gas train inlet lt Nipple Cap Follow good piping practices Pipe joint compound pipe dope must be resistant to corrosive action of fuel oil Apply sparingly only to male threads of pipe joints Supply and return piping should be sized to design conditions but not less than 12 O D continuous copper tubing Auxiliary fuel oil pump is recommended when suction line lift exceeds 12 feet Install swing joints so they will tighten as buried tank settles to prevent fuel line breakage Where iron pipe is required by local codes make swing joints with nipples and elbows several inches long on both suction and return line Locate close to tank Install manual shut off valve in suction line piping near burner and where piping enters building from outside tank Pitch suction line piping toward fuel tank Provide
3. a Size according to tables below For known flow rates or higher flow rate less than 20 F System return temperature rise through boiler see Figure 15 For unknown flow rates size piping per Figure 17 page page 15 using 20 F temperature rise through boiler AWARNING Flow at higher rates than shown in the tables in this manual for given pipe sizes can damage the boiler caus ing substantial property damage b Locate circulator in supply piping c For return piping use full diameter pipe for 10 times that NNN diameter before making any reduction For example a 4 inch Figure 15 Recommended minimum pipe sizes for return should not be reduced any closer to boiler return tap known flow rates note 1 ping than 40 inches d Install system blow off drain valve in lowest part of return Water flow rate Supply pipe size Return pipe size piping close to boiler ASME minimum size requirements are GPM A B given in Figure 17 page 15 2 2 a Closed type connect to 1 tapping K see page 11 Use 51 77 J a 1 NPT piping Any horizontal piping must pitch up toward tank at least 1 inch per each 5 feet of piping 78 142 4 4 js 143 237 5 5 b Diaphragm type Refer to tank manufacturer s literature for location Install automatic air vent in tapping 238 404 6 note 2 O c Connect cold water fill to expansion tank piping Figure 14 High temperature rise through boiler
4. Connect steam boiler piping continued Figure 25 Model 1288 through 1888 steam 3 or 4 risers required Mode HiserB Equalizer J T 1288 1488 g a P Tem V 1 i ine Dimenssans 1588 1688 5 5 P 40 4 15BB 1586 5 5 m 10 4 Drawing legend amp notes Figure 23 through Figure 26 Riser pipes one for each supply intermediate section Horizontal pipes needed to offset the header to allow for expansion and contraction of the header Steam supply must be located between last riser connection and egualizer elbow Egualizer elbow full size or reducing Egualizer pipe Condensate return line gravity or pumped Minimum 4 inches between water line and top of Hartford loop return nipple Boiler water line all automatic water level controls must be set to maintain this level 1 2 3 4 5 6 Close nipple at Hartford loop tee to reduce water hammer potential 7 8 9 4 Q Minimum 24 inches between water line and bottom of header 18 Part No 550 100 068 0308 Connect steam boiler piping continued Figure 26 Multiple Steam Boiler Piping Gravity Condensate Return NOTICE See page 18 for numbered circle references Pipe as shown for gravity return systems connect ing point A to the wet gravity return For pumped return systems install boiler water level control on each boiler with body mark at level indicat
5. amp return tappings Burner lengths Dimension F Supply tappings No amp size Return tappings No amp size Power Beckett Beckett _ Water Steam Water Fe 31 21 E E i 36 550 100 068 0308 Dimensions continued Figure 50 Dimensions see lettered dimensions on opposite page Be NPT Bl 2 1 M probe DWCO 1 NPT 1 NPT 65 3g tankless heater insertian remnaval REAR i Tankless healer openings 49 WM i S a 3 CM 4 F Boiler section assembly lengll INTERMEDIATE LEFT SIDE SECTION Part 550 100 068 0308 37 Parts Q3 8 1 2 3 4 5 6 amp 13 7 0 14 15 16 amp 18 y 19 0 2 n2 2 3 4 25 26 RO 7 DO 8 29 co Not shown Sealing rope gt 13 feet per joint 7 feet for burner plate 6 feet for flue collar Draw rod 5 8 11UNC 2A x 13 apply to front and rear sections Draw rod 5 8 11UNC 2A x 11 apply between intermediate sections Draft hood collar assembly includes damper collar damper damper quadrant locking plate swivel brackets and rope 10 inch 488 through 688 12 inch 788 and 888 14 inch 988 through 1388 16 inch 1488 through 1688 18 inch 1788 and 1888 Guadrant for flue collar Damper blade Damp
6. sections have been installed and the assembly is stable 10 Install intermediate sections as described on the following page Figure 6 Sealing rope installation g sealing ring Cut off rope even with edges sealing ring Bg Figure 7 Silicone sealant 7 3 zi hed vi i E 5 por instructions a Part No 550 100 068 0308 Assembling the block AWARNING Sections are top heavy Unbolted sections may fall if not supported resulting in severe personal injury or death Install intermediate sections 1 Remove and discard 4 diameter shipping tie rods 2 Remove grit from port machined surfaces with clean rag AWARNING Do not use petroleum based cleaning or sealing com pounds in boiler system Severe damage to system components can result causing substantial property damage 3 Position intermediate section so aligning lugs fit into sockets of next section See Figure 8 4 Install TI tankless intermediate and SI supply intermediate sections when used in order shown in Figure 9 page 10 5 Draw sections together until metal to metal contact is made around machined port openings see Figure 8 a b Oil threads on 4 draw rods Install washer and nut on end to be tightened Use nut only on other end Uniformly draw sections together starting at washer nut end NOTICE Important Leave an equ
7. Maximum gas consumption including any possible future expansion d Allowable loss in gas pressure from the gas meter outlet to the boiler 2 Minimum inlet natural gas pressure required at manual main shut off valve see the burner manual and material list 3 Follow good piping practices 4 Pipejoint compound pipe dope must be resistant to the corrosive action of liquefied petroleum gases and applied sparingly only to the male threads of pipe joints 5 A ground joint union must be installed in the piping to provide for servicing The supply piping must include a manual shut off valve and sediment trap See Figure 48 6 Piping must be supported by hangers not by the burner or its accessories Purge all air from the supply piping 8 All gas piping must be tested for leaks after installation Use soap suds mixture only Fuel oil piping yaa To prevent oil ow in case of oil line breakage Use anti syphon device when any part of the oil tank is above burner level Use check valve in suction line on burner side of manual shut off valve nearest tank when top of fuel oil tank is below burner level Failure to comply could result in fuel leakage or fire caus ing potential severe personal injury death or substantial property damage 1 two pipe fuel oil piping system is required for all installations 2 Supply and return lines must enter tank from top extending to within 4 to 6 inches from bottom of tank
8. See page 36 for boiler dimensions NOTICE Flue pipe breeching clearances take precedence over jacket clearances 4 Provide minimum clearances for servicing Left side for cleaning and tankless heater removal 39 inches Rear for breeching 36 inches Allow sufficient space on remaining sides for cleaning servicing and burner installation See burner literature for length and recommended service clearances Lay a foundation if needed 1 Floor construction and condition must be suitable for weight of boiler when filled with water See page 36 for approximate boiler operating weight 2 Alevel concrete or brick foundation constructed per Figure 1 and Figure 2 is required when a oor could possibly become ooded b Non level conditions exist 4 Part No 550 100 068 0308 Before installing boiler uo Combustion and ventilation air openings AWARNING Adequate combustion and ventilation air must be provided to assure proper combustion and prevent possibility of ue gas leakage and carbon monoxide emissions causing severe personal injury or death Do not install an exhaust fan in boiler room Incor rect burner operation can result When combustion and ventilation air enters through side wall openings ensure that the open ings comply with the requirements of Figure 3 and Figure 4 Opening sizes must comply with state provincial or local codes In the absence of local requirements use the Natio
9. a water softener for make up water if hardness exceeds 7 grains Freeze protection when used water boilers only 1 Use antifreeze especially made for hydronic systems Inhibited propylene glycol is recommended AWARNING Do not use automotive ethylene glycol or undiluted antifreeze Severe personal injury or death can result 2 50 solution provides protection to about 309F 3 Local codes may reguire back ow preventer or actual disconnect from city water supply 4 Determine guantity according to system water content Boiler water content is listed in Ratings page 35 Percent of solution will affect sizing of heat distribution units circulator and expansion tank 5 Follow antifreeze manufacturer s instructions To fill water boilers 1 Close manual air vents and drain cocks 2 Fillto correct system pressure Correct pressure will vary with each installation 3 Starting on lowest oor open air vents one at a time until water squirts out Close vent Repeat with remaining vents 4 Refill boiler to correct pressure To fill steam boilers 1 Do not fill except for leakage test until boiler is ready to be fired 2 Fill to normal waterline halfway up gauge glass 3 Recommend boiler water pH 7 0 to 8 5 2 Install fuel piping Gas piping 1 In sizing the gas piping the following factors should be consid ered a Diameter and length of the gas supply piping b Number of fittings c
10. and remove air vent boiler drain and gauge Remove 5 NPT Supply ries Figure 10 Boiler tapping locations and sizes see Figure 11 steam Water Y Steam relief valve and or High limit Skim tapping Manual reset limit Steam relief valve Water relief valve Secondary probe LWCO Not used Plug C1 amp C2 Low water cut offs Alternate low water cut offs C1 amp C2 01 amp D2 Alternate low water cut offs Firing rate temperature control when used Low water cut offs E1 amp E2 Gauge glass Rss F18 F2 Try cock tappings G 34 Pressure limit control Combination pressure Pressure operating control and temperature gauge pressure gauge Firing rate pressure control when used H 34 Boiler drain see Figure 17 Boiler drain page page 15 for system blow off drain valve locations and sizes K Piping to compression tank or EEMI 5 NPT Return automatic air vent Part No 550 100 068 0308 11 BEN C1 Combination high and low 9 o Complete block assembly Install burner mounting plate on front b Position sealing rope in groove section Secure assembly to section Use 10 32 x 94 truss head screws 1 Install four 1 2 x 34 studs to secure burner mounting plate to 2 Repeat above steps for back observation port as section sembly a Thread and lock together two nuts on rounded end of stud Thread at end of stud into one of four holes located around opening Insert HXT bars b Rem
11. boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 34 of this manual Failure to comply could result in severe personal injury 1 These parts must be on boiler a Plugs for unused tappings b Supply and return piping and steam supply header c Cleanout plates d Tankless heaters when used tankless heater cover plates when used tankless heater piping when used e Flue damper assembly f Observation port assemblies 2 These parts may be on boiler a Burner mounting plate and burner 3 These parts must be off boiler Water or steam gauge Limit control and low water cutoff Gauge glass and gauge glass cocks tri cocks Drain cock ence Remove jacket parts from cartons 1 Locate jacket cartons 2 Remove jacket parts from cartons as needed Leave in cartons as long as possible to avoid damage 3 Jacket parts are in the boxes listed below Part Box label descriptions Jacket screws in jacket corner boxes included in CRNR boxes Jacket support brackets amp hex nuts included in TRM CHNL boxes Jacket side support channels upper amp lower Jacket front rear support channels upper amp lower Jacket front panel Jacket back panel Jacket side and top panels Jacket corners Install support brackets channels 1 Place upper and lower support brackets over draw rods as shown in Figure 29 page 21 Place the brackets on the sections as given in
12. or spaces that 5 Before installing boiler uo freely communicate with the outdoors as follows e Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts each opening shall have a minimum free area of 1 in 4000 Btuh 550 mm kW of total input rating of all appliances in the enclosure Where communicating with the outdoors through horizon tal ducts each opening shall have a minimum free area of 1 in 2000 Btuh 1100 mm kW of total input rating of all appliances in the enclosure Outside openings ONE permanent opening method One permanent opening commencing within 12 inches 300 mm of the top of the enclosure shall be provided The appliance shall have clearances of at least 1 in 25 mm from the sides and back and 6 inches 150 mm from the front of the appliance The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following 1 1 in 3000 Btu hr 700 mm per kW of the total input rating of all appliances located in the enclosure and 2 Not less than the sum of the areas of all vent connectors in the space Combustion air combination indoor and outdoor openings ANSI NFPA 54 allows combustion air to be taken from a combination of openings to outside and to interior spaces Follo
13. panels In place Figure 31 Press jacket trim down over jacket front rear and side panels Part No 550 100 068 0308 Boiler manual tion Start Up Maintenance Parts um m Install jacket continues Figure 32 Jacket side panel placement 12 wide lf wide 8 wide B wide 16 wide 16 wide 14 wide 14 wide always always always always always always alway used on Used used on used an USEC us used oi i used pn Li right side left side right sine side hetwean i between right sida i lett sida ES front trant rel ta next 10 trant and front and in rear in rear rear rear rear panels rear panels position position pare panal M NS on lefi side side B 7 m i l tf E m a E E E amp SSSI a i i preme e e ea FEN aja lt 6 e 2 IT I re ype E ai alla S18 i i i l m l ae EE E E m Es a alla n AE AC EE HE 14 4 di 1 LJ i 1 _ b ec el al
14. product s In addition this warranty does not assume any liability of any nature for unsatisfactory perform ance caused by improper installation 3 Any costs for labor for removal and reinstallation of the alleged defective part transportation to Weil McLain if necessary and any other materials necessary to perform the exchange 4 Any products that have a failure or malfunction resulting from improper or negligent operation accident abuse freezing misuse unauthorized alteration or improper repair or maintenance 5 Improper adjustments including boiler burner control settings care or mainte nance Information is in the installation start up operations owner user s manuals service maintenance instructions and other printed technical informa tion provided with the product or direct from Weil McLain or weil mclain com April 1 2003 Indirect Fired Water Heaters Residential Water Heater Warranty Limited Lifetime Commercial Water Heater Warranty Limited 15 Year First Year Residential and Commercial Water Heaters Weil McLain warrants that its indirect fired water heaters are free from defects in material and workmanship for one year from the date of installation If any parts are found to be defective from such defects Weil McLain will provide replacement of such defective parts Second Year and Beyond Residential Only Second Through Fifth Years Commercial Only Weil McLain warrants that the tan
15. steps 4 through 6 Adjust as required Skim steam boilers NOTICE Clean all newly installed steam boilers to remove oil Failure to properly clean can result in violent water level uctuations water passing into steam mains or high maintenance costs on strainers traps and vents Skim boiler only Do not clean old piping or leaks can occur AWARNING Do not use petroleum based cleaning or sealing com pounds in boiler system Severe damage to system components can result causing substantial property damage Remove 2 plug from skim tapping tapping A see Fig ure 38 page 27 Provide 2 skim piping from tapping to oor drain Raise waterline to midpoint of skim piping Fire burner to maintain temperature below steaming rate during skimming process Feed in water to maintain water level Cycle burner ON OFF as needed to prevent rise in steam pres sure Continue skimming until discharge is clear This may take several hours Part No 550 100 068 0308 Figure 49 Flue collar damper assembly Lock nut slide down to open damper Test port with elbow and plug Damper 8 Drain boiler 9 While boiler is warm but not hot ush all inte rior surfaces under full pressure until drain water runs clear 10 Remove skim piping 11 Re insert plug at boiler skim tapping 12 Close drain cock 13 Fill with fresh water to normal water line 14 Start burner and steam for 15 minutes to remove di
16. tee and plug at highest point in suction line to release air from suction line and aid in priming Part No 550 100 068 0308 Make final adjustments Adjust burner and damper assembly 1 Lock ue damper OPEN Figure 49 AWARNING 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 severe property damage Refer to burner manual for start up and service Let burner advance to high fire Heat boiler to design conditions Using combustion test equipment adjust burner for a 12 4 CO for No 2 fuel oil 0 smoke b 9 10 CO natural gas COin ue gas not to exceed 50 ppm 0 0190 c Flue gas temperature no lower than 330 F NOTICE On some applications if draft conditions or burner char acteristics cause the burner ame pattern to impinge on the combustion chamber wall you may notice pinging sounds from the boiler Adjust the burner if possible to redirect the ame If this does not work contact your boiler supplier or Weil McLain to obtain an optional combustion chamber kit see page 38 for contents Adjust ue collar damper Figure 49 to ensure 0 1 W C positive pressure at test opening Tighten screws to secure in position Plug test opening with 1 8 plug provided with ue collar damper assembly Adjust barometric draft control when used to design condi tions Repeat
17. water areas soften cold domestic water supply to heaters to prevent lime build up Figure 34 Tankless heater ratings Weil McLain ratings Heater Intermittent Continuous Inlet and number draw GPM draw GPM ss outlet tappings note 2 notes 1 2 820 GPM based on 40 140 F DHW with boiler water Note 1 at 200 F Based on continuous draw with no recovery period Figure 35 Tankless Heater Piping Alte nate To automatic mixing valve and piping 25 Weil McLain 88 Water and steam boilers Series 2 for Gas Light Oil amp Gas Light Oil Fired Burners Install water boiler controls Install controls 1 Install furnished controls per Figure 36 and Figure 37 AWARNING Failure to properly install pipe and wire boiler controls C an result in severe damage to boiler building and per sonnel and is not covered by boiler warranty 2 Relief valve must be installed with spindle in vertical position Use fittings provided with boiler Do not make any other connection in that piping AWARNING Relief valve discharge line must be piped using rigid material suitable for 375 F threaded one end near oor close to 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 When installing low water cut off a Must be installed if boiler is located above radiation level b May be required on water
18. CH boiler The ow rate for each by pass circulator will be Flow x System circulator GPM of boilers 3 All circulators must run at the same time 4 Example For a 1 000 000 Btuh single boiler with system temperature drop of 20 F System GPM 1 000 000 20 500 100 GPM By pass 1 4 x 100 GPM 25 GPM Determine by pass circuit head loss for pipe size and fittings used 5 In most applications a standard booster pump should be adeguate Figure 19 Multiple water boiler piping B Fu EL La gt lt ict ge Cab a d ae a a A M E AT EN4D A J AT E a a poi 3 E 1 i 15 Connect steam boiler piping General steam piping information Figure 20 Cold water fill piping 1 Hartford loop piping arrangement and wet return are required for TT steam boilers Use the Hartford loop for both pumped return and 1 Cheek gravity return systems fill 2 Maintain 24 inch minimum from waterline to bottom of header 63 Manual eed from bottom of section isolation 3 When using condensate receiver feed pump must be energized by VEM Pressure reducing boiler mounted pump controller 4 Install piping when used To pnis return a Install piping as shown on page 17 through page 18forsingleboi ER E ers See page 19 for additional requirements when pip
19. Figure 27 Sections are numbered from front to back 2 Fasten each bracket loosely using two 5 8 nuts screwed onto the ends of the tie rods as shown NOTICE Models 488 through 988 do not require lower support brackets Only upper brackets are required Fasten all nuts and screws loosely during assembly to allow adjustment after all jacket frame parts are in stalled 20 Figure 27 Place support brackets as listed below Lower brackets on sections None None a mec 8 O __ 9 necem 9 3 Attach the upper channels to the upper supports as shown in callouts D 2 and Figure 29 page 21 Use two 10 x 1 2 screws at each bracket Models 988 and larger have two piece channels The side channels are labelled A and B in Fig ure 29 Figure 28 gives the lengths of the side channel parts for each model The channels at the boiler front and rear are part numbers 426400030 amp 426400031 re spectively Figure 28 Upper and lower side channel lengths Upper channel lengths Lower channel lengths inches inches N N N 2 4 4 s NA A A A A A 35 35 3 3 5 59 985 Epp 4 amp 8 EE ec 59 A A A A 42 42 50 58 58 ies 4 Attach the four jacket corners to the upper channels as shown in callout 6 Figure 29 page 21 Corner part numbers are 426400054 front left 055 front right 056
20. Minimum blow off model valve size 488 588 1 Piping multiple boilers 1 See Figure 18 Expansion tanks relief valves and other accessories are required but omitted from the illustration for simplicity 2 The boiler piping circuits are referred to as the secondary circuits in the following 3 The legend for Figure 18 and boiler pump sizing recommenda tions follow Size boiler pump GPM based on the following a b Temp rise High limit temp Return water temp GPM Boiler Gross Output Btuh Temperature rise x 500 Calculate only secondary boiler piping circuit resistance Al low for head loss through the boiler egual to three 90 degree elbows of secondary pipe size Operate each boiler and its pump with a Weil McLain boiler control panel Size secondary boiler circuitpipingusingthe owrateranges given in Figure 17 page 15 B Primary pump GPM and head calculation should not include secondary boiler circuits Primary pump can operate continuously during heating season Connection to primary circuit Space 12 maximum or as close as practical D Check valve E Hand valve Part No 550 100 068 0308 Figure 18 By pass piping for return water less than 140 By pass circulator Reium Y Min 10 pips ediamebers lkoll valves By pass circulator sizing 1 Size system circulator as required Determine GPM and head requirements 2 Provide a by pass circulator for EA
21. NIOSH web site at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this web site Wear long sleeved loose fitting clothing gloves and eye protection Operations such as sawing blowing tear out and spraying may generate airborne fiber concentra tion requiring additional protection Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thor oughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air Part No 550 100 068 0308 Ratings Boiler model number Net ratings Combustion Thermal Net Flue Positive Flue Boiler Packaged burner zB efficiency efficiency firebox gas pressure outlet boiler capacity volume volume in firebox diameter content weight Light oil Steam Water Cubic CFM Inches GPH MBH MBH feet W C a OA ERE RRREIE 3 E AAC IK an 3548 3974 1365 859 833 857 0 79 4423 1451 859 833 857 0 80 1 See below to specify complete model number 5 Gross ratings have been determined under the I B R provision governing forced draft boiler burner units Cs co Lg co o k Co ho co co co o 28 67 1 031 954 1 184 1 101 1 299 1 443 1 588 0 70 5600 M co N N co Co co co
22. PUNITIVE DAM AGES FOR BREACH OF ANY EXPRESS WARRANTY For prompt product war ranty claims notify the installer who in turn will notify the Weil McLain distributor from whom he purchased the boiler If this action does not result in warranty resolu tion contact Weil McLain Consumer Relations Department 500 Blaine Street Michi gan City Indiana 46360 with details in support of the warranty claim Alleged defec tive part or parts must be returned through the same trade channel in accordance with the Weil McLain procedure currently in force for handling returned goods for the purpose of inspection to determine cause of failure Weil McLain will furnish new part s to an authorized Weil McLain distributor who in turn will furnish the new part s to the heating contractor who installed the boiler If you have any questions about the coverage of this warranty contact Weil McLain at the address above Part No 550 141 950 0403 Weil McLain 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com tm WEIL MLAIN 40 Part No 550 100 068 0308
23. Um WEIL MLAIN EN Water amp steam boilers Series 2 for use with Gas Light Oil amp Gas Light Oil Fired Burners AWARNING This manual must only be used by a qualified heating installer service technician Read all instructions before installing Follow all in structions in proper order Failure to comply could result in severe personal injury death or substantial property damage NOTICE When calling or writing about the boiler Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket Boiler Manual INSTALLER USER e installation Maintenance e Startup Parts For additional information refer to Burner specification and data sheets for burners pre tested with model 88 boilers Consider piping and installation when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee This manual is for use only by your qualified heating installer service technician Boiler and burner must be installed by a qualified service technician We recom mend regular service by a qualified service technician at least annually Part No 550 100 068 0308 Read before proceeding Hazard Definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to impo
24. al amount of thread on each C end of the draw rod This is needed to allow securing the jacket support brackets in place The draw rods must not extend past the face of the front or back section or they will interfere with the jacket Draw rods should be torqued to a range of 90 to 100 ft lbs Do not back off draw rods Metal to metal contact will be achieved around port openings See Figure 8 If gap occurs it should be no greater than 032 Check with feeler gauge If for any reason gap around machined port opening exceeds 032 check for rope extending from rope grooves dirt on port openings or sockets or misaligned lugs If corrections are made and gap still exists contact your Weil McLain distributor or sales office before continuing installation Part No 550 100 068 0308 Figure 8 Sealing ring installation and port alignment Sect on Section Alignment a Socket Sor d psa sealant Meta to metal contact MEN Elastomer mH sealing nng ACAUTION 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 6 Repeat steps 1 5 7 Checkeach section for proper sealing rope position before proceeding to next section AWARNING Failure to position sealing rope properly can cause boiler to not seal g
25. as a iz E e m au alla E E Li j i 8 WC a ES zi Part No 550 100 068 0308 Install jac ket continued Figure 33 Jacket top panel placement 14 6 wide B wide 16 wide 16 wita 16 wide 14 6 wija always alwa place in Mace place in alvays FT HR FT used on 1P used next 2P positions SF positions SR positions RH used on top front tu RR shown shawn top rear 4 88 panel knockout amp nackout i is for is ior staam staar i 24 5 bailer boller P 5 riser riser moo 688 1788 2P 2P 2P SF 2P RR FT 2P 2P RR FT 888 1588 _ E L P RR FT 1488 FT 2P 2 2P RR 1088 1388 aadh 24 Part No 550 100 068 0308 Pipe tankless heaters ynya Hot water can scald DANGER 5 q Consumer Product Safety Commission and some states recommend domestic hot water tempera ture of 130 F or less When installing an automatic mixing valve se lection and installation must comply with valve manufacturer s recommendations and instruc tions Water heated to a temperature suitable for clothes washing dish washing and other sanitizing needs will scald and cause injury Children elderly infirm or physically handi capped persons are more likely to be injured by hot
26. as tight Gas tight seal prevents possible ue gas leakage and carbon monoxide emissions resulting in severe personal injury or death 8 Install remaining intermediate sections and front section using the same procedure If using tankless heater sections Install tankless heaters and gaskets or heater cover plates and gaskets Use 3 8 x 3 4 studs washers and nuts Assembling the block continue Figure 9 Section arrangement Boiler model Max Section arrangement number number all heaters must be on left side of boiler of W water S iN tankless F front B back I Intermediate heaters TI tankless intermediate SI supply intermediate steam only I can be substituted for sections EAST 000 2 1488W 6 1 MBBS 5 PATIKA Tee Tee SES ETE ISTIS I3 158 7 Fe Te Le Thee Thee Thee Te Le TI 15888 7 FOTIHISTIHESTI ESTIS SISTI EH TE DH TI 2B 1688W 7 Fe Tee Thee Thode TI DH TI DH TI HD TI 1 8 03688 7 o Be MeL TPL THe SITIS ESTE EH TE DH TI H Fe Te Le Thee Thee Thode TE Le TE TH TI HD TI BBS Re Tee Te SISTI HE THe Le TIS SISTI ETE DH TI eB 188W Fe Tee Le TIS Le TE 2H TE DH TI HD TI 00188800 6 FETIHISTIH ESSI IH TI IS TI LS Stee TI HD 10 Part No 550 100 068 0308 Boiler manual Installation Start Up Maintenance Parts Perfor
27. ate receiver capacity required Boiler I B R gross output Gallons condensate Minimum condensate receiver capacity gallons Note 1 Recommended condensate model number 16 steam per hour per hour feed pump capacity 15 minute boiler 30 minute boiler 45 minute boiler 60 minute boiler GPM at 15 PSI operation operation operation operation 557 8 8 98 1888 6 0 75 1607 16 Part No 550 100 068 0308 2 2 2 2 2 4 4 4 4 Connect steam boiler piping continued ACAUTION Improperly piped systems or undersized piping can Figure 23 Model 488 through 688 steam 1 riser contribute to erratic boiler operation and possible boiler or system damage Piping system must be installed as shown using pipe sizes shown Pipe sizes shown are for two pipe pumped return systems Adjust pipe sizing as needed when connecting to gravity return systems Consult local Weil McLain distributor or sales office before installing alternate piping Steam boiler piping guidelines Minimum height of header above water line must be 24 inches AWARNING The boiler header must always be at least 24 inches above the water line as shown in all steam boiler piping diagrams Installing the pipe lower will result in increased water carryover to the system resulting in potential seri ous damage to system components and oxygen corrosion 19 due to excess make up water ij Hartford loop piping for all steam boi
28. back left and 057 back right 5 Attach the lower side front and rear channels to the jacket corners as shown in callouts and 5 of Figure 29 page 21 Models 1088 and larger have two piece side channels The channels are labelled A and B in Figure 29 Figure 28 gives the lengths of these parts for each model Front and rear lower channels are part numbers 426400032 and 426400033 Part No 550 100 068 0308 Install jac ket continued Figure 29 Installing jacket support brackets support channels and corners piping and other components omitted for clarity Upper right support bracket Upper left support bracket Lower support brackets a 8 Insert 10 x Phillips pan head screws A Side channel pieces front and rear Corner attachments to Comer attachments to Corner attachments to lower front and rear channels lower channels upper channels Part No 550 100 068 0308 21 Install jac ket continued Install jacket front and back panels 1 Slide the jacket front and back panels down over the top channels and into the bottom channels as shown in Figure 30 2 Slide the upper and lower channels as needed to square up the fit Install jacket side panels 1 Remove jacket side panels from cartons 2 Before installing side panels square up the jacket support rails Place any of the jacket side panels on the rails as shown in Figure 30 Butt the side panel against
29. boilers by certain state local or ter ritorial codes or insurance companies c Install low water cutoff designed for water installations where shown in Figure 36 and Figure 37 4 Ifinstallation is to comply with ASME installation requirements an additional high temperature limit is needed Purchase and install in supply line between boiler and isolation valve or in tapping A 5 Duallimit control settings a Low set according to design requirements b High at least 20 higher than low limit 240 F maximum 6 Install optional controls per control manufacturer s instructions Figure 36 Water control tappings see Figure 37 i A 2 High limit Manual reset limit B at Water relief valve C1 amp C2 Alternate low water cut offs C1 Combination high and low limit control D1 amp D2 1 Firing rate temperature control when used Low water cut offs Combination pressure temperature gauge Piping to compression tank or automatic air vent 26 Figure 37 Water control locations D1 F1 F2 D2 2 NPT 8 NPT Supply 5 5 NPT Return Part No 550 100 068 0308 Boiler manual Installation Start Up Maintenance Parts Install steam boiler controls Install controls Figure 39 Steam control locations 1 Install controls where shown in Figure 38 and Figure 39 01 5 NPT Supply r K AWARNING Failure to properly install pipe and wire boiler control
30. e before pump control operates Primary level level control control aU LWCO in tapping L Blowdown iX Xx Blowdown valve valve 28 Part No 550 100 068 0308 Connect breeching and venting systems General venting information 1 Model 88 boilers operate with positive overfire pressure Adjust damper assembly see Figure 49 page 33 during burner start up to achieve 0 1 W C positive pressure at damper sample hole Select type of venting system Forced draft Boiler breeching and stub vent operate at positive pressure Entire system must be gas tight to prevent leaks Stub vent height must be limited to prevent negative draft with 3 foot minimum stub vent height above roof See Figure 44 and Figure 46 Balanced draft Boiler operates with positive pressure overfire Chimney may provide excess draft which may require a barometric draft control installed and set to provide minimum draft to maintain 0 1 posi tive pressure at ue collar Minimum chimney height above roof is 3 feet See Figure 45 and Figure 47 Construct metal breeching 1 See Figure 43 for minimum breeching diameter 2 Select material type and thickness in compliance with local codes AWARNING Conventional ue pipe should not be used as it could 1 eak ue gases and carbon monoxide emissions through seams and joints resulting in severe personal injury or death 3 Refer to ASHRAE Guide fo
31. echnician particularly if ame outages or pilot outages are common Periodically check the odorant level of your gas Inspect boiler and system at least yearly to make sure all gas piping is leak tight Consult your propane supplier regarding installation of a gas leak detector There are some products on the market intended for this purpose Your supplier may be able to suggest an appropriate device Part No 550 100 068 0308 Contents Before installing boiler 4 Set boiler 7 Assembling the block 8 Perform hydrostatic pressure 11 Complete block 12 Connect water boiler piping 14 Connect steam boiler piping 16 20 Pipe tankless heaters 25 Install water boiler controls 26 Install steam boiler controls 27 Connect breeching and venting systems 29 Install burner amp wiring and fill system 31 install tuel piping 32 Make final adjustments 33 Handling ceramic fiber and fiberglass materials 34 35 Dimensions ore 36 38 Warranty APT 40 Part No 550 100 068 0308 Before installing boiler Installation must comply with Figure 1 Boiler foundation when required 1 State provinc
32. ective heat exchanger upon the payment of a proportionate charge based on the time the boiler has been in service The proportionate charge will be egual to the appropriate percentage of the list price of such heat exchanger at the time the warranty claim is made and will be determined as follows 11th year 10 12th year 20 13th year 40 14th year 60 15th year 80 16th year amp beyond 100 This warranty does not cover boilers operated with combustion air contaminated externally by chemical vapors or with improper fuel additives or with water system conditions which may have caused heat exchanger failure See section For all Weil McLain Products for additional warranty information For All Weil McLain Products These warranties are subject to the condition that the Weil McLain Product s must have been installed in accordance with manufacturers instructions by a heating contractor whose principal occupation is the sale and installation of plumbing heating and or air conditioning eguipment These warranties extend only to the first retail purchaser of the products and only to a product that has not been moved from its original installation site In addition to each product warranty listed Weil McLain warranties do not cover 1 Components that are part of the heating system products but were not fur nished by Weil McLain as a part of the heating system products 2 The workmanship of any installer of Weil McLain s
33. ed in Figure 42 page 28 Provide at point A either Separate feed pumps and check valves for each boiler or Single feed pump with separate solenoid valve for each boiler For pumped return systems install a combination oat and thermostatic trap on each boiler to prevent ooding of one boiler while other boiler is firing Install trap in skim tapping see Figure 39 page 27 Connect traps to condensate receiver Gravity return systems are self levelling if the wet returns are piped to the common system wet return Install boiler piping as shown in the preceding pages of this manual Part No 550 100 068 0308 D Install stop valves per ASME code requirements For pump return systems if using automatic steam valves use only slow opening automatic valves Use a Weil McLain Boiler Control Sys tem such as a BCP panel to open each steam valve automatically before firing burner E Construct common supply drop header with pipe size at least same size as largest boiler header size F Use e A Weil McLain Boiler Control System such as a BCP panel with header mounted pressure control s to sequence boilers or A steam pressure controller G Install drip line in common supply drop header Gravity return Pipe drip line to wet return e Pumped return Use combination oat and thermostatic trap and drain to condensate receiver 19 Install jacket Before installing jacket AWARNING The
34. er locking plate Cleanout plate Woven fiberglass gasket for cleanout plate Observation port assembly includes frame rope gasket plugs and sight glass a Assembly b Sight glass only Part number 316 301 210 316 301 212 316 301 214 316 301 211 316 301 213 386 300 213 Order for specific burner 590 735 140 590 291 909 590 317 579 450 030 934 560 134 505 560 134 495 340 004 606 340 004 607 340 004 608 340 004 609 340 004 612 330 056 634 460 003 646 563 530 784 450 030 965 590 317 305 383 600 099 591 419 199 590 317 580 Washer gasket for sight glass 2 x 1 x inches Sealing rope 38 1 foot per observation port Burner mounting plate studs gt x 3 inches Cleanout plate nut 14 Cap screw 2 13 x 34 Observation port screw 10 32 x 17 Flue collar cap screw 2 x 1 Flue collar washer 11 6 Burner mounting plate washer 72 Burner mounting plate nut 1 2 Draw rod nut Cleanout plate washer 14 Cleanout plate carriage bolt 14 x 134 HXT bars see Figure 12 page 12 for installation and placement details for HXT bars d 3 flueway kit includes 3 sets of bars 590 317 150 Obtain locally Obtain locally Obtain locally Obtain locally Obtain locally Obtain locally Obtain locally Obtain locally Obtain locally Obtain locally 416 400 130 Obtain locally 416 400 131 e 2 flueway kit includes 2 sets of bars Combustion chamber liner kit opti
35. ial and local plumbing heating and electrical codes 7 Regulations of servicing utilities ASME Section Low Pressure Boiler and Pressure Vessel Code m National Fuel Gas Code ANSI NFPA 54 when applicable National codes where applicable gt Before selecting boiler location 3 MM 1 Check for nearby connections to gt Meu m TUN 28 a Fuel supply MEL a b Electrical power blas na System water or steam piping MEN 90 o d Venting systems see page 29 am Combustion and ventilation air supply see page 5 Minimum u 2 Check area around boiler Remove any combustible materials gasoline and other ammable vapors and liquids A WARNING Failure to keep boiler area clear and free of combustible materials gasoline and other ammable liquids and vapors can result in severe personal injury death and Figure 2 Boiler foundation see Figure 1 substantial property damage Boiler model Length L minimum inches Provide clearance around boiler number 1 Provide minimum clearances to combustible materials Boiler top 24 inches Boiler front 48 inches Boiler flue 9 inches Boiler rear 9 inches Boiler sides 6 inches Single wall vent pipe 18 inches Double wall vent pipe refer to vent pipe manufacturer s recommendations for vent pipe clearances 2 Boiler may be installed on combustible ooring 3
36. ing multiple boilers b Return pipe sizing e Pumped return Size return piping by pump e Gravity return Size gravity return same as Hartford loop equalizer pipe size c Drain valve Install system drain valve in lowest part of return System condansate netur piping close to boiler See Figure 17 page 15 for sizing d Cold water fill piping Connect cold water fill piping as shown in Figure 21 Condensate piping to boiler Figure 20 Also shown are recommended valves and water meter ventie abrosghere 4 m i if used Water meter will detect added makeup water indicating Pu leaks in system on Condensate return piping Satisfactory operation of any steam heating system depends on orm re adeguate return of condensate to maintain steady water level HER concensedte retur 1 1 1 h o a Avoid adding excessive amounts of raw make up water AA Check valve pr a e Where condensate return is not adequate a low water cutoff aa Wo Wo a vee e e L uu with pump control condensate receiver and condensate boiler MES DU m M aal E i feed pump should be installed a Strainer water till piging Manual igclatior valve See Figure 21 for piping and Figure 22 for sizing See Figure 14 Tei Figure 22 Condens
37. is permissible when boiler to the same location as the expansion tank connects to the flow at high velocities may damage any boiler 6 inch piping requires nipples and 5 x 6 reducing couplings system when diaphragm type tank provided with 1288 through 1888 boilers only The total pressure drop through the 1888 boiler using the nipple and reducing coupling will not exceed 14 PSI For smaller boilers the pressure drop will be less d Also shown are recommended valves and water meter when used Water meter will detect added make up water indicating leaks in system 14 Part No 550 100 068 0308 Connect water boiler piping continued Figu re 16 Recommended minimum pipe sizes when flow rate is not known see Figure 14 page page 14 note 1 Boiler Supply pipe size Return pipe size model A B 488 3 3 588 788 4 4 888 1188 5 5 1 Figu 288 1888 6 note 2 6 note 2 Pipe sizes are based on a 20 F temperature rise through the boiler For applications with higher flow rates lower temperature rise determine the flow rate and use Figure 15 page page 14 to size the piping 6 inch piping requires nipples and 5 x 6 reducing couplings provided with 1288 through 1888 boilers only The total pressure drop through the 1888 boiler using the nipple and reducing coupling will not exceed PSI For smaller boilers the pressure drop will be less 17 ASME drain valve size Boiler
38. ive parts It is expressly understood that failure as a result of freezing of water within the pipes tubing does not constitute a defect in material or workmanship and shall not be covered by this warranty See section For all Weil McLain Products for additional warranty information Parts and Accessories Parts and Accessories Warranty Limited 1 Year Weil McLain warrants that parts and accessories that were purchased through Weil McLain are free from defects in material and workmanship for one year from the date of installation If any parts and or accessories are found to be defective from such defects during such time period Weil McLain will provide replacement of such defective parts Parts and accessories covered under this warranty include only those items that are not covered under other Weil McLain product warranties See section For all Weil McLain Products for additional warranty information NOTE Residential warranties do not cover any residential products installed in build ings other than one or two family dwelling units unless they are buildings with indi vidual residential products for each dwelling unit THE WARRANTIES DESCRIBED HEREIN ARE IN LIEU OF ALL OTHER WAR RANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IM PLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MER CHANTABILITY WEIL McLAIN EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL INCIDENTAL INDIRECT OR
39. k assembly components of its indirect fired water heaters are free from defects in material and workmanship for the second through the fifth year from the date of installation commercial only or for the second year from the date of installation and beyond for residential only If during such time periods a leak in the tank assembly should occur Weil McLain will provide replace ment for the original tank assembly Sixth Year through Fifteenth Year Commercial Only Weil McLain warrants that the tank assembly components of its commercial indirect fired water heaters are free from defects in material and workmanship for the sixth year through the fifteenth year following the date of installation If during such time period a leak in the tank assembly should occur Weil McLain will provide replacement for such defective tank assembly Such replacement will be furnished with the nearest comparable model available from Weil McLain at the time of such replacement and upon payment of a proportionate charge Proportionate charges will be egual to the appropriate percent age of the current list price of such commercial indirect fired water heater at the time warranty claim is made and will be determined as follows 6th amp 7th year 55 8th amp 9th year 60 10th amp 11th year 65 12th amp 13th year 70 14th amp 15th year 75 These warranties do not cover 1 Any water heater not initially installed with a new temperature pressure
40. kim tapping 2 2 Steam relief valve L Secondary probe low water cut off C1 amp C2 Low water cut offs see Figure 42 page 28 T Se 01 amp 02 Alternate low water cut offs see Figure 42 page 28 E1 amp E2 Gauge glass F1 amp F2 Try cock tappings G 34 Pressure limit control Pressure operating control and pressure gauge Firing rate pressure control when used H Boiler drain see Figure 17 page page 15 for system blow off drain valve locations and sizes oo SS ee 5 NPT Return Part No 550 100 068 0308 27 Install steam boiler controls continued Figure 40 Steam control siphon and fittings Figure 41 Float type water level control locations Primary water level Casting line Back up water level Casting line control height above control height above bottom of gauge bottom of gauge glass glass _ w e 150MD 157MD see Note 3 93 193 94 see Note 3 51 2 amp 51 S 2 see Note 3 Notes Other manufacturer s controls providing similar function may be used if properly located and selected Use low water cut off function only Pump controller function must only be handled by the primary control When pump control is used with feedwater tank install pump control on boiler and make up water feeder on tank Use separate low water cutoff on boiler when back up is needed Do not install combination low water cutoff and feeder as back up control on boiler Feeder will operat
41. lers 1 You must install the system supply pipe between the equalizer elbow and the last boiler riser pipe connection to the header This assists in separating water from the steam as it turns upward into iL S BH the steam supply pipc Pi Model Hiser A Header H ill 2 Locate the top of the Hartford loop return nipple at least 4 inches EN 48000 2s below the water line as shown NOH 1688 5 2 Figure 24 Model 788 through 1188 steam 2 risers required Drawing legend amp notes Figure 23 through Figure 26 1 Riser pipes one for each supply intermediate section Horizontal pipes needed to offset the header to allow for expansion and contraction of the header Steam supply must be located between last riser connection and equalizer elbow Equalizer elbow full size or reducing Equalizer pipe Close nipple at Hartford loop tee to reduce water hammer potential Condensate return line gravity or pumped Minimum 4 inches between water line and top of Hartford loop return nipple oe Boiler water line all automatic water level gt 4 ipi controls must be set to maintain this level FUR fydol Piler Hiser 8 HeederH Equalizer J Minimum 24 inches between water line and YBH a x pu bottom of header BEB xw me deae amp 1088 5 1100 2 OW 1 2 Part 550 100 068 0308 17
42. m hydrostatic pressure test Prepare boiler and test Figure 11 Boiler tappings 1 See Figure 10 and Figure 11 for tapping locations Install a Boiler drain not furnished D1 b Water pressure gauge for test only Be sure gauge can handle test pressure see step 3 c Air vent in upper tapping K F1 2 Plug remaining tappings ACAUTION Do not pressure test with any control installed Damage to control can occur due to overpressure 3 Fill boiler Vent all air Pressure test at least 10 minutes at a pressure D2 not less than the following a Steam boiler Between 45 and 55 psig b Water boiler 1 times maximum allowable working pressure MAWP stamped on the boiler nameplate located on boiler jacket front panel NOTICE Do not exceed above test pressures by more than 10 psig AWARNING Do not leave boiler unattended Cold water fill could expand and cause excessive pressure resulting in severe personal injury death or substantial property damage 4 Check for maintained gauge pressure and leaks Repair if found AWARNING Leaks must be repaired at once Failure to do so can dam age boiler resulting in substantial property damage AWARNING Do not use petroleum based cleaning or sealing com pounds in boiler system Severe damage to system components can result causing substantial property 3 2 NPT damage plugs from tappings that will be used for controls and accesso 5 Drain boiler
43. n different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors oors having a total minimum free area of 2 1117 1000 Btuh 4400 mm kW of total input rating of all appliances Part No 550 100 068 0308 Figure 3 Combustion and ventilation air openings Boiler room below grade Grating minimum 12 above averace snow line 7 Mote Size af araaway and grating to be equal to or greater than total lauvar area a all SM cu 2 r Boiler reer fear LN zz Y Areaway LOL er Figure 4 Combustion and ventilation air openings Boiler room partially or completely above grade Louver minimum 27 12 average snow line AS LM d a Lu ws 1 rJ Duct size equal to total louver area og ee ee T ie i EU r Beile i Combustion air openings to outside Outdoor combustion air can be taken through per manent openings TWO or ONE as described in the following The minimum dimension of air openings shall not be less than 3 inches 80 mm Outside openings TWO permanent openings method Two permanent openings one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclo sure shall be provided The openings shall communicate directly or by ducts with the outdoors
44. nal Fuel Gas Code ANSI NFPA 54 The following information is taken from ANSI NFPA 54 For details and information not addressed below refer to the standard Combustion air openings to inside Required volume of interior spaces ANSI NFPA 54 allows combustion air to be supplied through openings to interior spaces if the volume of the connected interior spaces meets the minimum volume required by the standard The minimum volume of interior spaces can be taken as 50 cubic feet per 1 000 Btuh of all appliances in the spaces or the minimum volume can be calculated using the formulas given in ANSI NFPA 54 Excep tion If the air infiltration rate for the spaces is known to be less than 0 40 air changes per hour the minimum volume must be calculated as specified in the standard Inside air opening sizes and locations For spaces that provide the minimum volume required by ANSI NFPA 54 the air openings must be sized per the following Combining spaces on the same story Each opening shall have a minimum free area of 1 in 1000 Btuh 2200 mm kW of the total input rating of all appliances in the space but not less than 100 in 0 06 m One opening shall commence within 12 inches 300 mm of the top and one opening shall commence within 12 inches 300 mm of the bottom of the enclosure The minimum dimension of air openings shall be not less than 3 inches 80 mm Combining spaces in different stories The volumes of spaces i
45. ng and pick up allowance of 1 15 pel tee Le ME Steam ratings based on the following allowances 488 588 AB Faclory asserbled sections boilerburner uril Field assembled bailes burner unit 1 333 688 1 323 788 1 301 888 1 289 988 1888 1 288 An additional allowance should be made for gravity hot water systems Burner input based on maximum of 2 000 feet altitude For other or for unusual piping and pick up loads altitudes consult Weil McLain distributor agent or sales office Consult local Weil McLain distributor agent or sales office No 2 fuel oil Commercial Standard Spec CS75 56 Heating value of oil 140 000 Btu per gallon Gas pressure required at burner gas train inlet for rated burner input based on 1 000 Btu per cubic foot natural gas specific gravity of 0 60 Refer to burner manual for required pressure Flue collar connection is oval 16 x 19 With 0 10 W C positive pressure at flue collar Water boilers tested for 80 PSIG ASME water working pressure Steam boilers tested for 15 PSIG ASME steam working pressure Part No 550 100 068 0308 35 Dimensions Dimensions inches 2338 4 mx wn BW ex s SUN o mx m 4 _ gx mn AU _ mx mW AN 004000 65 A E NEN EON mw 30 38 46 54 62 70 78 94 102 126 134 42 Supply
46. nting plate ACAUTION Maintain gas tight seal between burner mounting ange and plate to prevent damage to air tube 4 Level burner using burner support brackets where required 5 Secure with furnished bolts 6 Retain burner information packet Keep with boiler To wire burner and boiler controls AWARNING Electric shock hazard Can cause severe personal injury or d r death if power source is not disconnected before installing or servicing boiler and burner 1 Install all wiring in compliance with National Electrical Code ANSI NFPA 70 Any additional national state or local codes 2 Follow burner manual and wiring diagram found in burner in formation packet 3 Use 14 AWG wire for operating and safety circuit wiring Where burner motor voltage differs from control voltage supply proper voltage to each Size fused disconnects and conductors per National Electrical Code ANSI NFPA 70 Determine if water treatment is needed water boilers only AWARNING Do not use petroleum based cleaning or sealing com pounds in boiler system Severe damage to system components can result causing substantial property damage Continual make up water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure Part No 550 100 068 0308 For unusually hard water areas or low pH conditions less than 7 0 consult local water treatment company Provide
47. o 28 67 32 20 32 20 35 76 39 26 42 79 46 32 49 85 0 70 0 71 TRO Co Oo N N co co o co o 0 71 N NO NO N N Oo co co o co o 0 72 D o NS gt oO oo N 0 74 1735 075 P w gt co N 1 854 2 003 1 945 0 76 Co co co co 53 38 0 77 53 38 0 78 N gt co co o co Go o N Ni EN o o o o a EM LL NEN NEW NEW gt 56 91 60 44 2152 2 303 co a BB BUT NE Based on average water temperature of 170 F in heat distributing NK units Number Blank ar W far F opacity of water Rimer km Flue gas volume at outlet temperature sections duced Sior forced Uwn GL Gas Dil rating stam Net I B lt R ratings are based on net installed radiation of sufficient quantity for the requirements of the building Sailer withaut burner and burner mounting plate Nothing need be added for normal piping and pick up Tr unit with Tactory assembled sections Water ratings are based on a pipi
48. ocument was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH web site at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this web site Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thor oughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air REMOVAL OR INSTALLATION OF FIBERGLASS WOOL AWARNING This product contains fiberglass jacket insulation and ceramic fiber materials in jacket insulation burner front plate insulation and cleanout plate gaskets Airborne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for fiberglass wool at the time this document was written Other types of respira tors may be needed depending on the job site conditions Current NIOSH recommendations can be found on the
49. oilers are free from defects in material and workmanship for the eleventh year and beyond from the date of installation If during such time period any section s is found to be defective Weil McLain will provide replacement of such defective section s upon the payment of a proportionate charge based on the time the boiler has been in service The proportionate charge will be egual to the appropriate percentage of the list price of such section s at the time the warranty claim is made and will be determined as follows 11th year 5 12th year 10 13th year 15 14th year 20 15th year 25 16th year 30 17th year 35 18th year 40 19th year 45 20th year 50 21st year 55 22nd year 60 23rd year 65 24th year 7090 25th year amp beyond 7590 These warranties do not cover boilers operated with combustion air contam inated externally by chemical vapors or with improper fuel additives or with water conditions which may have caused unusual deposits in the cast iron sections See section For all Weil McLain Products for additional warranty information Weil McLain 24a Cast Aluminum Boilers Residential Warranty Limited 15 Year includes 5 Year Ultra Protection Plan Commercial Warranty Limited 15 Year does NOT include Ultra HPP First Through Fifth Year Weil McLain warrants that its cast aluminum boilers are free from defects in material and workmanship for one year from the date of installation and the heat e
50. onal includes ceramic fiber blanket for left side wall plus water glass adhesive see page 33 Consult your local Weil McLain sales office for details Contact local Weil McLain sales office Part No 550 100 068 0308 Boiler manual Installation Start Up Maintenance Parts Pa rts continued Figure 51 Parts Part No 550 100 068 0308 29 Warranty Weil McLain Limited Warranties Residential amp Commercial Cast Iron Boilers Residential Water Warranty Limited Lifetime Residential Steam Warranty Limited 10 Year Commercial Warranty Limited 10 Year First Year All Residential amp Commercial Cast Iron Boilers Weil McLain warrants that its cast iron boilers are free from defects in material and workman ship for one year from date of installation If any parts are found to be defective from such defects Weil McLain will provide replacement of such defective parts Second Through Tenth Year Residential amp Commercial Water S team Weil McLain warrants that the cast iron sections of its water and steam boilers are free from defects in material and workmanship from the date of installation for the second through the tenth year If during such time any section is found to be defective Weil McLain will provide replacement of such defective section s Eleventh Year and Beyond Residential Water Only Weil McLain warrants that the cast iron sections of its residential water b
51. ottom blue tipped HXT bar first row af pins beneath the bottom cleanout plate boss DO NOT instal a bottom blue HXT bar between front section and first intermediate section Blue tipped HXT bar 34 inches long 12 Part No 550 100 068 0308 Complete block assembly coninueg NOTICE DO NOT insert a bottom HXT bar into the opening between the FRONT section and the first intermediate section 3 To remove ue HXT bars when required to clean the boiler ueways grab the end of each HXT bar with pliers and pull straight out Clean HXT bars and replace as shown in Fig ure 12 page 12 Install cleanout plates AWARNING Cleanout plates must be installed gas tight to prevent possibility of ue gas leakage and carbon monoxide emissions resulting in severe personal injury or death See Figure 13 2 Position two 1 4 x 134 carriage bolts in cleanout opening be tween the cleanout plate bosses as shown Secure with washers and nuts 3 Place woven fiberglass gasket over carriage bolts Mount cleanout plate over opening Secure with nuts and wash ers 5 Repeat steps I through 3 for remaining cleanout plates Install draft hood collar 1 Install 4 continuous bead of sealing rope adhesive in groove on draft hood collar 2 Position 2 sealing rope in groove Overlap ends of rope at least 1 inch 3 Mount collar over ueway outlet on back section Secure with 1 x 1 hex head cap screws and washer
52. ove nuts c Repeat steps and b for remaining studs 1 See Figure 12 page 12 2 Install burner mounting plate 2 Flue HXT bars are identified by painted ends They must be inserted as shown with the HXT bars in the sequence Top position a Apply continuous bead of sealing rope adhesive in groove around opening in section b Position 2 sealing rope in groove Overlap ends at least one inch red tipped HXT bar 24 inches long c Install burner mounting plate with part number and the word place on the top row of pins positioned at top Use 2 washers and nuts Middle position white tipped HXT bar 26 inches long Install observation port assemblies on front place on the first row of pins below the top clean out plate boss and back sections 1 Install front observation port assembly blue tipped HXT bar 34 inches long a Apply 4 continuous bead of sealing rope adhesive in groove place on the first row of pins below the on observation port bottom cleanout plate boss Figure 12 Insert HXT bars through cleanout openings as shown below omit the bottom blue tipped HXT bar in the opening between the front section and the first intermediate section Slide top red tipped HXT bar onto top row of pins slide middle white tipped HXT bar ante first row of pins beneath the top cleanoutplate boss Red tipped HXT bar 24 inches long White tipped HXT bar 26 inches long slide b
53. r chimney and breeching calculations and construction and lining AWARNING Long horizontal breechings excessive number of tees and elbows or other obstructions restricting combustion gas ow can result in possibility of condensation ue gas leakage and carbon monoxide emissions causing severe personal injury or death Part No 550 100 068 0308 Figure 43 Minimum breeching diameter vent or liner diameter inches Forced draft as co 19 Balanced draft 12 15 15 18 18 18 21 21 21 24 24 24 24 24 27 Boiler flue collar dimensions inches 10 round 29 Connect breeching and venting systems Figure 44 Stub vent forced draft single boiler 15 feet typical E e LE Figure 45 Conventional chimney balanced draft with barometric draft control when required single boiler 30 Figure 46 Stub vent forced draft multiple Figure 47 Conventional chimney balanced draft with barometric draft control when required multiple boilers Part No 550 100 068 0308 Install burner amp wiring and fill system To install burner 1 Unpack burner 2 Place gasket around air tube and against burner mounting ange If sealing rope is used apply continuous bead of rope adhesive around burner mounting ange and apply sealing rope to make gas tight seal 3 Mount burner into opening in burner mou
54. relief valve bearing the listing of the American Society of Mechanical Engineers A S M E at the time of the water heater installation 2 Any water heater that has a failure or malfunction resulting from a failure to keep the tank full of potable water b failure to assure that water in the tank is free to circulate at all times or c failure to keep the tank free of water sediment or scale deposits 3 Any water heater that has potable water in the unit with a chloride or chlorine content higher than 80 mg liter 4 Any water heater installed in a residence containing any type of water softener system that is not installed and maintained in accordance with manufacturer s specifications 5 Any water heater installation where non metallic piping products without an oxygen barrier are used 6 Any water heater used for non potable application such as pool or process heating See section For all Weil McLain Products for additional warranty information Radiant Heating Products Radiant Heating Products Warranty Limited 30 Year amp IPC Products Warranty Limited Year Weil McLain warrants that its AlumiPex and Oual Pex radiant heating products are free from defects in material and workmanship for thirty years three years for IPP and IPC products from the date of installation If any parts are found to be defective from such defects during such time period Weil McLain will provide replacement of such defect
55. rtant information concern ing the life of the product INN a Indicates presence of hazards that will cause severe personal injury death or substantial property damage if ignored AWARNING Indicates presence of hazards that can cause severe personal injury d eath or substantial property damage if ignored ACAUTION Indicates presence of hazards that will or can cause minor personal injury death or substantial property damage if ignored NOTICE Indicates special instructions on installation operation or maintenance that are important but not related to personal injury Read before proceeding AWARNING Read all instructions before installing Failure to follow all instructions in proper order can cause severe personal injury death or substantial property damage AWARNING Do not use petroleum based cleaning or sealing components in boiler system Severe damage to system components can result causing sub stantial property damage AWARNING Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Propane gas can accumulate at level Smell near oor for the gas odorant or any unusual odor If you suspect a leak do not attempt to light the burner Use caution when attempting to light a propane burner or pilot burner This should be done by a qualified service t
56. s Part No 550 100 068 0308 Figure 13 Cleanout plate assembly Bolt amp washer ES Woven fiberglass x d gasket ba Eo 3 4 E GCleanout e gt plate i Washer i 2 i m Nut 4 TAT bh gt edn il 2 Nut PF y a ar i LU A WARNING The boiler contains ceramic fiber and fiberglass materials Use care when han dling these materials per instructions on page 34 of this manual Failure to comply could result in severe personal injury Io Connect water boiler piping General water piping information Figure 14 Water boiler piping typical 1 System water supply and return piping should be installed and piping connections attached to boiler before erecting jacket or installing controls 2 Donot pipe in through supply and out through return This creates reverse water ow through boiler that must not be used 3 When installing in a system in which return water temperature can drop below 1409F apply the by pass piping with by pass pump as shown in Install piping Install piping as shown in Figure 14 page 14 and Figure 18 page 15 1f applicable for single boilers For multiple boilers see Fig ure 19 page 15 frent only ACAUTION Improperly piped systems or undersized piping can contribute to erratic boiler operation and possible boiler or system damage 1 Connect supply and return piping
57. s E Ff an result in severe damage to boiler building and per sonnel and is not covered by boiler warranty F1 a Install steam pressure operating and high limit controls and pressure gauge See Figure 38 Figure 39 and Figure 40 page 28 F2 Pressure limit control settings e Low set according to design requirements e High set at least 2 psi higher than low limit 15 psi maxi Dz mum b Relief valve must be installed with spindle in vertical position Use fittings provided with boiler Do not make any other con nection in that piping AWARNING Pipe relief valve discharge through vertical piping to at mosphere Use rigid material suitable for 375 F threaded one end only Install drain pan elbow to drain condensate Pipenear oorcloseto oor 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 c Install water level controls and gauge glass per Figure 38 Figure 39 and Figure 42 page 28 Fittings for controls to be furnished by others If water level control is not shown in Figure 41 page 28 locate casting mark on control and install per manufac turer s instructions 2 NPT NOTICE Do not use water level controls with quick hook up fit tings Nuisance shutdowns will occur f 5 NPT Supply Figure 38 Steam control tappings see Figure 39 sn 00000002 A i Steam relief valve and or S
58. ssolved gases 15 Stop burner 16 Check traps and air vents for proper operation Check boiler for gas tight seal AWARNING Boiler must be sealed gas tight to prevent possible flue gas leakage and carbon monoxide emissions resulting in severe personal injury or death 1 Remove boiler jacket side and top panels AWARNING The boiler contains ceramic fiber and berglass materials Use care when han dling these materials per instructions on page 38 of this manual Failure to comply could result in severe personal injury 2 Start burner Observe all sealing points and chalk mark any not gas tight 3 seal all chalk marked areas a Use silicone sealant on section ueways b Check gaskets and sealing rope placement 4 Reinstall all jacket panels 22 Handling ceramic fiber and fiberglass materials 34 REMOVAL OF FRONT PLATE OR CLEANOUT PLATE MATERIALS The burner front plate and cleanout plate gaskets contain ceramic fiber materials Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA re quirements for cristobalite at the time this d
59. the jacket corner panel Push pull on the upper and lower channels until the fit up of the side panel corner panel and channels is square e Place a jacket top panel in position against the jacket front panel to ensure the top alignment is square Adjust the jacket support rails forward or backward if needed for square alignment Tighten the 5 8 inch nuts on the upper and lower support brackets Tighten the screws securing the upper and lower rails to the support brackets the screws securing the front and back panels to the rails 3 Apply all jacket side panels in the order shown in Figure 32 Remove jacket knockouts as required for tankless heaters and tankless heater openings Note that panel sequence is not important for boilers not equipped with tankless heater intermediate sections Install jacket top panels 1 Place jacket top panels as shown in Figure 33 page 24 e Remove knockouts for riser pipes and air bleed piping front section using tin snips Install jacket trim 2 Press jacket trim down over the front and side jacket panels as shown in Figure 31 22 Figure 30 Installing removing jacket front rear and side panels When servicing Lift trim up ta Tr access panels Tm replace after Servicing Jacket panel flange fits over upper Upper Shanna Slids panel down to install Slide side panel up to remove Flanges of lower channels hold jacket
60. ubstantial property damage 6 Inspect block assembly for disjointed sections Check gas tight seal of ue collector hood and cleanout plates Part No 550 100 068 0308 Figure 5 Section assembly lifting weights Boiler Approximate Minimum model lifting sling length number weight from crane hook to pounds boiler lifting lugs AWARNING Gas tight seal must be maintained to pre vent possible ue gas leakage and carbon monoxide emissions resulting in severe personal injury or death a Check inside section assembly for any light passing through unsealed areas b Mark all unsealed areas c At unsealed areas check for Damaged gaskets Sealing rope not in place e Loose bolts or nuts d Correct all conditions and repeat step b If un sealed areas still exist contact your Weil McLain distributor or sales office before continuing installation 7 Proceed to Perform hydrostatic pressure test page 11 Assembling the block AWARNING Sections are top heavy Unbolted sections may fall if not supported resulting in severe personal injury or death Prepare and position back section 1 Apply continuous bead of sealing rope adhesive in sealing rope grooves See Figure 6 Do not get any adhesive on machined port surfaces Place 2 sealing rope in groove Around curves grasp at 1 intervals and push together Do not stretch AWARNING Do not pre cut rope Gas tight seal must be maintained
61. ve boiler from skid Cables are already attached to block as sembly See Figure 5 for lifting weight Using crane hook middle of each cable to eye of crane Using hoist hook middle of each cable to hoist Raise boiler off skid Use pipe rollers under skid angles to roll boiler 4 Place boiler in final position Center boiler on foundation if used 5 Level boiler Shim under skid angles if necessary Cut off cables AWARNING Cables are not intended for long term usage Cables may corrode inside boiler weakening their lifting strength Failure to remove cables can result in severe personal injury death or substantial property damage 7 Proceed to Perform hydrostatic pressure test page 11 For block assembly 1 Remove lag screws 2 in front 2 in rear from shipping rails 2 Remove boiler from skid Cables are already attached to block as sembly See Figure 5 for lifting weight Using crane attach free end of cables to eye of crane Using hoist attach free end of cables to hoist Raise boiler off skid Use pipe rollers under steel skid angles to roll boiler 3 Place boiler in final position Center boiler on foundation if used Level boiler Shim under skid angles if necessary 5 Cut off cables AWARNING Cables are not intended for long term usage Cables may corrode inside boiler weakening their lifting strength Failure to remove cables can result in severe personal injury death or s
62. ver and grille design and free area are not known it shall be assumed that wood louvers will have 25 percent free area and metal louvers and grilles will have 75 percent free area Non motorized louvers and grilles shall be fixed in the open position Minimum screen mesh size Screens shall not be smaller than 1 4 inch mesh Motorized louvers Motorized louvers shall be interlocked with the appli ance so they are proven in the full open position prior to main burner ignition and during main burner opera tion Means shall be proved to prevent the main burner from igniting should the louver fail to open during burner startup and to shut down the main burner if the louvers close during burner operation Part No 550 100 068 0308 Set boiler in place AWARNING Ensure the equipment and cables used for lifting are designed to handle the load See Figure 5 for approximate weights of model 88 section assemblies Failure to comply can result in severe personal injury death or substantial property damage For packaged boiler 1 Remove top jacket panels Set aside until after boiler is piped AWARNING The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on Handling ceramic fiber and fiberglass materials page 34 of this manual Failure to comply could result in severe personal injury Remove lag screws 2 in front 2 in rear from shipping rails 3 Remo
63. w all requirements of the standard to determine the minimum volume of interior spaces and to calculate minimum sizes of openings Engineered Installations Engineered combustion air installations shall provide an adequate sup ply of combustion ventilation and dilution air and shall he approved by the authority having jurisdiction Mechanical Combustion Air Supply Where all combustion air is provided by a mechanical air supply system the combustion air shall be supplied from outdoors at the minimum rate of 0 35 ft minute per 1000 Btuh 0 034 m min per kW for all appliances located within the space Where exhaust fans are installed in the building additional air shall be provided to replace the exhausted air Each of the appliances served shall be inter locked to the mechanical air supply system to prevent main burner operation where the me chanical air supply system is not in operation Where combustion air is provided by the build ing s mechanical ventilation system the system shall provide the specified combustion air rate in addition to the reguired ventilation air Louvers Grilles and Screens The reguired size of openings for combustion venti lation and dilution air shall be based on the net free area of each opening Where the free area through a design of louver or grille or screen is Known it shall be used in calculating the size opening reguired to provide the free area specified Where the lou
64. 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 Part No 550 100 068 0308 To pipe tankless heaters See Figure 35 2 Size piping no smaller than heater inlet and out let 3 Automatic mixing valve must be installed See Figure 35 Follow manufacturer s instructions to install 4 Flowregulating valve must be installed Size accord ing to continuous draw of heater See Figure 34 Follow manufacturer s instructions to install 5 Operating control with small adjustable differen tial scale is recommended Install in temperature control tapping in heater plate 6 Multiple tankless heaters see Figure 35 a Use cold water supply header with individual risers to each heater Size header by increasing one pipe size for each additional heater b Use hot water outlet header with individual risers to each heater Size header by increasing one pipe size for each additional heater c Do not pipe multiple heaters in series 7 In hard
65. xchanger is free from defects in material and workmanship for five years from the date of installation If any parts in the first year or the heat exchanger in the first five years are found to be defective from such defecis Weil McLain will provide replacement of such defective parts or heat exchanger In addition to the product warranty W eil McLain will provide a 5 Y ear Uta Homeowner P rotection Plan UHPP for residential applications only to cover parts and labor for five years from the date of installation provided only if tne Ultra boiler is properly registered with the UHPP Administrator within one month of the date of installation UHPP claims must be process ed directly through the P lan Administrator and not through Weil McLain Sixth Through Tenth Year Weil McLain warrants that the heat exchangers of its cast aluminum boilers are free from defects in material and workmanship for the sixth through the tenth year from the date of installation If during such time the heat exchanger is found to be defective Weil McLain will provide replacement of such defective heat exchanger Eleventh Through Fifteenth Year Weil McLain warrants that the heat exchangers of its cast aluminum boilers are free from defects in material and workmanship for the eleventh through fifteenth year from the date of installation If during such time period the heat exchanger is found to be defective Weil McLain will provide replacement for such def

Weil-McLain 88 Boiler User Manual

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