Weil-McLain 80 Boiler User Manual
Contents
1. Pipe as shown for gravity return systems connecting D Install stop valves per ASME code requirements point to the wet gravity return For pump return systems if using automatic steam For pumped return systems install boiler water level valves use only slow opening automatic valves Use a control on each boiler with body mark at level indicated Weil McLain Boiler Control System such as a BCP in Figure 30 on page 30 Provide at point A either panel to open each steam valve automatically before Separate feed pumps and check valves for each firing burner boiler Or E Construct common supply drop header with pipe size Single feed pump with separate solenoid valve for at least same size as largest boiler header size each boiler mE F Use B For pumped return systems install a combination float AWeil McLain Boiler Control System such asa BCP and thermostatic trap on each boiler to prevent flooding of one boiler while other boiler is firing Install trap in skim tapping see page 29 Connect traps to condensate receiver 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 systems are self levelling if the wet AMA returns are piped to the common system wet return Gravity return Pipe drip line to wet return Install boiler piping as shown in this manual pages 16 Pumped return Use c2. 9 Install jacket continued Figure 23 Jacket side panel placement Models 780 880 and 980 4 Ml 6 au 0 4 00 07 813151 5 800 052 425 832 059 425 800 54 425 800 05 475 600 060 425 800 053 425 800 058 Roald 31 Lal 3 38 425 800 059 425 800 052 425 800 051 425 800 050 425 800 053 425 800 058 Mam 10 17 orga 8680 Loit side Fight side r 12 eh i ee 127 8 d ch 85 2 T 425 800 3 F 425 B00 054 425 300 054 825 800 451 425 000 4060 425 800 153 425 51 53 F 425 800 058 2 Hale Flaked 980 Lett side 24 Part No 550 141 935 0602 9 Install jacket continued Figure 24 Jacket side panel placement Models 1080 1180 and 1280 opa 085 og A zi WB ym 085 0 EFM SF lt a We rr 9 Gr a lat Po Sor gt 7 ao 25 Part No 550 141 935 0602 9 Install jacket continued Figure 25 Jacket top panel placement gt alli coe 1 BOILER F
3. or to important information concerning the life of the product DANGER Indicates presence of hazards that will cause severe personal injury death or substantial property damage if ignored WARNING Indicates presence of hazards that can cause severe personal injury death or substantial property damage if ignored CAUTION Indicates presence of hazards that will or can cause minor personal injury 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 WARNING Read all instructions before installing WARNING Do not use petroleum based cleaning or Failure to follow all instructions in proper sealing components in boiler system order can cause severe personal injury Severe damage to system components can death or substantial property damage result causing substantial property damage Part No 550 141 935 0602 1 Before installing boiler Installation must comply with Lay a foundation if needed e State provincial and local plumbing heating and Floor construction and condition must be suitable for electrical codes weight of boiler when filled with water See page 34 for Regulations of servicing utilities approximate boiler operating weight A level concrete or brick foundation constructed per Table 1 and Figure 1 is required when Before
4. 35 for boiler dimensions on cA NOTICE Flue pipe breeching clearances take Minimum 8042 precedence over jacket clearances Left side for cleaning and tankless heater removal 34 inches Allow sufficient space on remaining sides for cleaning servicing and burner installation See burner literature for length and recommended service clearances Part No 550 141 935 0602 3 Before installing boiler continued Provide combustion and ventilation air openings WARNING Do not install an exhaust fan in boiler room Adeguate combustion and ventilation air must be provided to assure proper combustion and prevent possibility of flue gas leakage and carbon monoxide emissions causing severe personal injury or death Opening sizes must comply with state provincial or local codes In their absence use the following when boiler is in a confined room Provide two permanent openings in boiler room one within 12 inches of ceiling one within 12 inches of floor Minimum dimension of each opening is 3 inches 1 When all air is taken from within building each opening should be at least one sguare inch 1 000 Btuh boiler input and freely connect with areas having adeguate infiltration from outside 2 When all air is taken from outdoors each opening should connect directly or by ducts from outdoors or crawl or attic spaces that freely connect with outdoors and sized as listed below a through out
5. Low set according to design requirements High at least 20 higher than low limit 240 F maximum 6 Install optional controls per control manufacturer s instructions Figure 27 Water control locations D1 G NOTE D is tapped inte top of section Optional 1 5 A 1 tapping Back section note 2 Table 11 BO D F1 x a F2 en 2 Optional inspection tapping note 2 Table 11 L an 3 NPT 3 NPT Return 2016 Return 29 Part No 550 141 935 0602 12 Install steam boiler controls Install controls Table 12 Steam control tappings see Figure 28 1 Install controls where shown in Table 12 and Figure 28 WARNING Failure to properly install pipe and wire Tapping Steam boilers with water level controls boiler controls can result in severe damage ere Float type primary Float type primary to boiler building and personnel and is Probe type secondary Float type secondary not covered by boiler warranty 1 a Install steam pressure operating and high limit Ua controls and pressure gauge See Figure 28 this page and Figure 29 page 30 Pressure limit control settings Low set according to design requirements High set at least 2 psi higher than low limit 15 psi maximum b Relief valve must be installed with spindle in vertical position Use fitt
6. Only cleanout plates upper brackets are required tankless heater s when used 3 Spacethe brackets along the length of the boiler so there tankless heater cover plate s when used are close to an equal number of sections on either side tankless heater piping when used of the bracket s flue damper assembly 4 Attach the upper and lower rails on each side of the flue collector hood boiler b 1 ith 10 x 32 Observation port assemblies de DA 9 70 screws DO NOT tighten the screws more than finger 4 These parts may be on boiler tight burner mounting plate burner Install jacket front and rear panels 5 These parts must be off boiler water or steam gauge limit control low water cutoff 1 Attach the front and rear jacket panels to the upper and lower channels using 10 x 1 2 Phillips pan head screws as shown in Figure 20 gauge glass and gauge glass cocks 2 Rearflue boilers only remove rear jacket panel flue tri cocks collector transition knockout with tin snips before drain cock installing on boiler Part No 550 141 935 0602 9 Install jacket continued Figure 20 Installing jacket support brackets and rails and jacket front and rear panels ETT uu Sd v x M pnilipe AUS yts here Apply Upper right support bracket Upper rails side nigh Lower rail Lower rail 5 Insert 10 x Ye Phillips pan head sc
7. carbon monoxide emissions causing severe personal injury or death Table 14 Minimum breeching diameter forced draft venting I B R recommended Flue collar outlet minimum vent diameter diameter Boiler model number Table 15 Minimum breeching diameter balanced draft venting I B R round vent rectangular chimney diameter chimney vent height diameter Boiler model number 1 29 628 NR NN Ean ie 09 28 0 9 BEN 27 14 Install burner To install burner 1 Unpack burner CAUTION Maintain gas tight seal between burner mounting flange and plate to prevent damage to air tube gasket around air tube and against burner mounting flange 4 Level burner using burner support brackets where required If sealing rope is used apply 4 continuous bead of rope adhesive th furnished bol around burner mounting flange and apply sealing rope to make 76 gas tight seal 6 Retain burner information packet Keep with boiler 3 Mount burner into opening in burner mounting plate 15 Wiring and fuel piping Electric shock hazard Can cause severe personal injury or death if power source is not disconnected before installing or servicing boiler and burner To wire burner and boiler controls To install gas and or oil piping Install all piping in compliance with Local state or national codes and regulatio
8. 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 thoroughly NIOSH stated First Aid M Eye Irrigate immediately BI Breathing Fresh air REMOVAL OF FIBERGLASS WOOL OR INSTALLATION OF FIBERGLASS WOOL COMBUSTION CHAMBER LINING OR BASE PANELS WARNING This product contains fiberglass jacket insulation and ceramic fiber materials in combustion chamber lining or base panels in gas fired products 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 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 Operations such as sawing blowing tear out and spraying may generate a
9. nuts b Gradually tighten all bolts and nuts on flue collector assembly and boiler Tighten to between 30 and 35 inch pounds torque See WARNING above Alternate locations as you tighten the fasteners to ensure all parts are evenly drawn down with no gaps or distortion of parts 5 Install damper and flue caps see Figure 11 page 13 a b C Wipe item 5 Figure 10 flue damper flange surface and flue collector assembly surfaces with a clean rag Position round gasket item 7 Figure 10 on flue collector assembly in the flue location shown in Figure 11 page 13 Align bolt holes Place flue damper assembly on gasket See NOTICE below Insert 10 x 10 screws through the holes Alternate from screw to screw and tighten all screws evenly and securely NOTICE Model 380 top flue applications always mount the damper assembly with the damper adjustment plate pointed toward the rear of the boiler as shown in Figure 11 Otherwise the jacket top panels may be difficult to install Install flue cap on remaining top opening if any using steps a through c above After installing flue collector ALL BOILERS 1 Check for gas tight seal of all flue collector hood components a o oe collector hood joints must be sealed gas tight to prevent possible flue gas leakage and carbon monoxide emissions resulting in severe personal injury or death Open flue damper Visually inspect
10. or maintenance Information is included in the installation Instructions Owner s Information Manual and or Start up Service and Maintenance Instructions and other printed technical material furnished by Weil McLain with the boiler 5 Boilers operated with combustion air contaminated externally by chemical vapors or with improper fuel additives or with water conditions which may have caused unusual deposits in the cast iron sections These warranties extend only to the first retail purchaser of the boiler and only to a boiler that has not been moved from its original installation site THE WARRANTIES DESCRIBED ABOVE ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY WEIL McLAIN EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL INCIDENTAL INDIRECT OR PUNITIVE DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY For prompt product warranty 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 resolution contact Weil McLain Consumer Relations Department 500 Blaine Street Michigan City Indiana 46360 2388 with details in support of the warranty claim Alleged defective part or parts must be returned through trade channels accordance with the Weil McLain procedure currently in force for handling
11. pickup Water ratings are based on a piping and pickup allowance of 1 15 Steam ratings are based on the following allowances 380 thru 1180 1 333 1280 1 321 An additional allowance should be made for gravity hot water systems or for unusual piping and pickup loads Consult locat Weil McLain representative Stack gas volume at outlet temperature 8 With 0 10 W C positive pressure at flue collar NOTICE Boiler sections are tested for 80 PSIG working pressure Water boilers are supplied with 30 PSIG relief valve standard 34 Part No 550 141 935 0602 Dimensions and ratings continued 10 11 5 34 minimum Vig for heater removal 5 k gt AT 5 6 4 14 3 NPT retun 4 24 74 B FRONT BACK 57 56 pply outlets 4 su 36 10 Ve L Boiler jacket length INTERMEDIATE 025 SIDE Part No 550 141 935 0602 35 2 18 Parts Intermediate section regular Intermediate section with special side tappings Intermediate section supply steam boilers 315 700 120 315 700 130 315 700 150 Intermediate section tankless 315 700 140 10 not shown Section assembly kit includes for one joint sealing rope sealing rope ad
12. 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 or air conditioning equipment tom WEIL MLAIN above Weil McLain 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com
13. to do so can damage boiler resulting in substantial property damage WARNING Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to system components can result causing substantial property damage 5 Drain boiler and remove air vent boiler drain and gauge Remove plugs from tappings that will be used for controls and accessories Part No 550 141 935 0602 5 Complete block assembly Install burner mounting plate on front section 1 Install four 1 2 x 434 studs to secure burner mounting plate to section a Thread and lock together two nuts on rounded end of stud Thread flat end of stud into one C 2 Install burner mounting plate of four holes located around opening b Remove nuts Repeat steps a and b for remaining studs a Apply 4 continuous bead of sealing rope adhesive in groove around opening in section b Position 1 2 sealing rope in groove Overlap ends at least one inch C Install burner mounting plate Use 12 washers and nuts Install observation port assemblies on front and back sections 1 Install front observation port assembly a Apply continuous bead of sealing rope adhesive in groove on observation port b Position 2 sealing rope in groove C Secure assembly to section Use 5 6 18 x 4 slotted head screws 2 Repeat above steps for back observation port assembly Install cleanout plates Cleanout plates must be instal
14. 0 141 935 0602 33 Dimensions and ratings model number L _12 _ 88 20 1 6 A 56 5 5 pras 3 20 21 3 27 26 1 5 62 63 1 2 9 0 5 9 6 2 3 4 5 2 3 2 3 25 Note Use piping connections shown in Manual pages 14 through 19 DE p 2 3 Boiler I B R model burner capacity number Positive Flue Boiler Packaged Approx pressure in outlet water content boiler operating firebox diameter gallons weight weight less water with water Cu ft CFM Inches Inches Water Steam Lbs Lbs W C boiler to waterline Steam Water MBH MBH no BEN ro EX oolalol 5 8 60 1080 960 1378 1110 8471 118 0 2923 3456 1180 10 60 69 129 5 3068 3697 72 141 0 1040 3313 4038 Notes 1 Burner input based on maximum of 2 000 feet altitude For higher altitudes consult local Weil McLain representative 2 No 2 fuel oil Commercial Standard Spec 0575 56 Heat value of oil 140 000 Btu Gal 3 Consult Weil McLain Burner Specifications and Data Sheet for gas pressures required 4 MBH refers to thousands of Btu per hour 5 Gross l B R ratings have been determined under the I B R provision forced draft boiler burner units 6 Netl B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and
15. 30 Primary water Casting line level control height above bottom of gauge glass 42 150MD 157MD see Notes 2 amp 3 93 193 see Notes 2 amp 3 51 2 amp 51 S 2 see Notes 2 amp 3 Notes Table 13 Water level control locations Back up water level control Casting line Back up height above only bottom of probe type gauge glass water level control in tapping MM PS801 120 Or Hydrolevel 45 550 Other manufacturer s controls providing similar function may be used if properly located and selected Cannot be used as back up water level controls When pump control is used with feed water tank install pump control on boiler and makup 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 operate before pump control operates Primary water level control Blowdown Valve Part No 550 141 935 0602 13 Connect breeching and venting systems General venting information Model 80 boilers operate with positive overfire pressure Adjust damper assembly see 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 lea
16. CIAL WARRANTY Limited 10 Year NOTE The residential steam and water warranties do not cover residential boilers installed in buildings other than one or two family dwelling units unless they are buildings with individual boilers for each dwelling unit First Year All Residential amp Commercial Cast Iron Boilers Limited Warranty for Cast Iron Boilers Weil McLain warrants that its cast iron boilers are free from defects in material and workmanship for one year from the date of installation If any parts are found to be defective in manufacture Weil McLain will provide replacement of such defective parts Second Through Tenth Year Residential Water Steam Second Through Tenth Year Commercial Water Steam Limited Warranty for cast iron sections 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 period any section is found to be defective Weil McLain will provide replacement for the original cast iron section s Eleventh Year and Beyond Residential Water Only Limited Warranty for Cast Iron Sections Weil McLain warrants that the cast iron sections of its residential water boilers 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 defectiv
17. Piping for multiple boilers see Figure 13 Figure 13 Multiple water boiler piping A Size secondary boiler pump GPM based on following formulas Gross output Temperature rise x 500 Temperature rise F 230 F Return water temperature Gross output is in Btuh Calculate only secondary piping circuit resistance Boiler resistance will be about equal to three 90 degree elbows of secondary pipe size Operate each boiler and its secondary pump from a Weil McLain boiler control panel Do not maintain boiler at predetermined water temperature B Primary pump GPM and head calculation should not include secondary boiler circuits Primary pump can operate continuously during heating season C Space 12 maximum or as close as practical D Check valve E Hand valve Expansion tank s relief valves and other accessories are required but not shown Part No 550 141 935 0602 I5 16 Connect steam boiler piping General steam piping information Hartford loop piping arrangement and wet return are required for steam boilers Use the Hartford loop for both pumped return and gravity return systems Maintain 24 inch minimum from waterline to bottom of header 5644 from bottom of section When using condensate receiver feed pump must be energized by boiler mounted pump controller Install piping Install piping as shown on pages 16 through 18 for single boilers See page 19 for additional req
18. RONT T UL BOILER FRONT BOILER FRONT 26 BOILER FRONT BOILER FRONT BOILER FRONT BOILER FRONT BOILER FRONT Part No 550 141 935 0602 10 Pipe tankless heaters To pipe tankless heaters Table 10 Tankless Heater Ratings Size piping no smaller than heater inlet and outlet Tankless Continuous draw Inlet and outlet 2 Automatic mixing valve must be installed See Figure 26 heater model no recovery period tappings Follow manufacturer s instructions to install GPM 3 Flow regulating valve must be installed Size according to continuous draw of heater See Table 10 Follow manufacturer s instructions to install 4 Operating control with small adjustable differential scale is recommended Install in temperature control tapping in heater plate Figure 26 Tankless Heater Piping 5 Multiple tankless heaters see Figure 26 a Usecold water supply header with individual risers Alternate to each heater Size header by increasing one pipe poc d size for each additional heater b Use hot water outlet header with individual risers E di E di to each heater Size header by increasing one pipe r size for each additional heater mous mixing valve c Do not pipe multiple heaters in series P i 6 In hard water areas soften cold domestic water supply fm to heaters to prevent lime build u
19. Water amp steam boilers for use with Gas Light Oil amp Gas Light Oil Fired Burners WEIL McLAIN MODEL SO Boiler Manual WARNING This manual must only be used by a gualified heating installer service technician Read all instructions before installing Follow all instructions in proper order Failure to comply could result in severe personal injury death or substantial property damage INSTALLER 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 USER technician Boiler and burner must be installed by a qualified service technician Werecommend regular service by a qualified service technician at least annually 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 NOTICE Part No 550 141 935 0602 Contents Page 1 Before installing boiler 2 2 eere eere eee nnn 3 2 Set boiler in 0000 0 0 T 5 3 Assemble block Ae E DE ET 6 4 Perform hydrostatic pressure test 8 5 Complete block assembly 9 6 Install flue collector
20. age boiler causing substantial property damage b Locate circulator in supply piping c Forreturn piping use full diameter pipe for 10 times that diameter before making any reduction For example a 4 inch return should not be reduced any closer to boiler return tapping than 40 inches d Install system blow off drain valve in lowest part of return piping close to boiler ASME minimum size requirements are shown in Table 5 2 Install expansion tank a Closed type connect to 1 tapping K refer to pages 28 and 29 Use 1 N P T piping Any horizontal piping must pitch up toward tank at least 1 inch per each 5 feet of piping b Diaphragm type Refer to tank manufacturer s literature for location Install automatic air vent in K tapping c Connect cold water fill to expansion tank piping See Figure 12 page 14 Also shown are recommended valves and water meter when used Water meter will detect added make up water indicating leaks in system Table 5 Hecommended minimum pipe sizes when flow rate is not known see Figure 12 14 Table6 Recommended minimum pipe sizes for known flow rates Water flow rate Supply AEE size GPM Table 7 ASME drain valve size Valve size 34 Figure 12 Water boiler piping typical System supply front only System return Iront or rear 0 Part No 550 141 935 0602 7 Connect water boiler piping continued 3
21. aht Oil Gac L Ail Firar Weil McLain 80 Boiler For Gas P Li a ht Oil aS L ic jh 11 Oil Fired Burners 9 Connect steam boiler piping continued Figure 17 Model 1080 through 1280 steam boiler piping NOTE minimum 24 inches between boiler water line and bottom of header Figure 18 Condensate piping to boiler Table 9 Condensate receiver capacity System condensate return Boiler l B R Gallons Minimum condensate receiver Recommended model gross condensate Capacity gallons Note 1 condensate number output per hour feed pump lbs steam 15 minute 45 minute 60 minute capacity oer per hour boiler boiler boiler GPM at 15 PSI operation operation operation operation ENEE 7 28200 E EN Vent atmosphere To boiler 1 condensate ratum Check valve Manual isolation valve N n o ol mo Fand pump 46 5 E 5 Cold water fil piping 1 Manual isolation valve Sae Figura 14 paga 16 5 12 EK Note 1 Maximum time to when condensate returns to boiler co EM EN EN 1 ECH 72 EN 8 45 2 18 Part No 550 141 002 e Installation Start Up Maintenance Parts 9 Connect steam boiler piping continued Figure 19 Multiple Steam Boiler Piping Gravity Condensate Return
22. anged bolts and flanged nuts Tighten to between 30 and 35 inch pounds torque See WARNING on page 12 top right column 5 For 880 1280 a Stand remaining hood module on end as in Figure 8 right side b Wipe all flanged surfaces with clean rag c Lay gasket on flange d Carefully place open end of first module on top of gasket aligning flanged surfaces e Secure with seven 5 6 x 5 4 flanged bolts and flanged nuts Tighten to between 30 and 35 inch pounds torque See WARNING on page 12 6 Attach flat stitched sealing rope to hood assembly See Figure 9 a Lay hood on floor with flanged side up b Wipe flanged surface with clean rag to remove dirt and oil Apply double faced tape to flanged surface d Apply rope to tape beginning on one side of open end of hood leaving 4 extending past edge Bend rope around corners DO NOT cut or stretch rope WARNING Do not pre cut rope All collector hood joints must be sealed gas tight to prevent possible flue gas leakage and carbon monoxide emissions resulting in severe personal injury or death e Continue around entire flange At other open end leave 14 rope extending past edge of flange Cut off excess rope 3 Double faced tape serves only to hold sealing rope in place during installation It will disintegrate over time If collector hood and sealing rope are removed for any reason install new tape and new gasket NOTICE Figu
23. b in top panel side flange next to top flue knockout to prevent top panel from sagging see below Tab Top panel side flange 3 Install trim collar around damper assembly on top flue boilers 0050 Install jacket trim 1 Press jacket trim over jacket side panels as shown in Figure 21 Place each jacket trim so the side of the trim with small holes faces toward the boiler Figure 21 Trim collar Top panels Trim Side panels 24 Installing removing jacket side panels and top panels Lift trim off of jacket side panel replace after servicing Side panel flange fits over upper rail Slide side panel up to remove 6 down to install Installing or removing side panels Flanges of lower rail hold side panel in place Part No 550 141 935 0602 9 Install jacket continued Figure 22 Jacket side panel placement Models 380 480 580 and 680 7098 pai HA 2 4 2 7 425 800 056 425 400 056 Rotated 475 800 084 428 800 051 475 800 151 Left sita Lati sica 12 Ae ee 080 de 12 425 800 058 Aotated 425 200 059 4125 800 061 Let side bei ia BE cH 425 800 05B Rotated 425 00 050 475 800 043 Rotated 660 Latt zida Part No 550 141 935 0602 os 5 23
24. causing substantial property monoxide emissions resulting in severe damage personal injury or death 1 Remove 1 plug from skim tapping tapping A 1 Remove boiler jacket side and top panels Figure 28 page 29 Provide 142 skim piping from tapping to floor drain pipe to side of boiler WARNING The boiler contains ceramic fiber and Vb HP fiberglass materials Use care when 2 Raise waterline to midpoint of skim piping handling these materials per instructions 3 Fire burner to maintain temperature below steaming on page 38 of this manual Failure to rate during skimming process comply could result in severe personal 4 Feedin water to maintain water level Cycle burner to 90 prevent rise in steam pressure 2 Startburner Observe all sealing points and chalk mark 5 Continue skimming until discharge is clear This may any not gas tight take several hours 3 To seal all chalk marked areas 6 Drain boiler While boiler is warm but not hot flush a use silicone sealant on section flueways all interior surfaces under full pressure until drain water b check gaskets and sealing rope placement runs clear 4 Reinstall all jacket panels 7 Remove skim piping Re insert plug at boiler skim tapping 8 Close drain cock Fill with fresh water to normal water line Start burner and steam for 15 minutes to remove dissolved gases Stop burner 9 Checktraps and air vents for proper operation Part No 55
25. chined port openings see Figure 6 a Oilthreads on 4 draw rods Install washer and nut on end to be tightened Use nut only on other end b Uniformly draw sections together starting at washer nut end NOTICE Important Leave an equal amount of thread on each end of the draw rod This is needed to allow securing the jacket support brackets in place see pages 20 and 21 c Draw rods should be torqued to a range of 90 to 100 ft Ibs Do not back off draw rods d Metal to metal contact will be achieved around port openings See Figure 6 If gap occurs it should be no greater than 032 Check with feeler gauge e 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 6 CAUTION 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 7 Repeat steps 1 5 from Prepare back section page 6 Install bottom refractory blanket on combustion chamber floor inside section block 1 2 a 4 Unroll and install blanket per steps 2 and 3 as each intermediate and front Unroll blanket only to depth of back section and first intermediate section Spread adhesive on botto
26. d down bolts in the sections Place the collector hood assembly so its rear flange is against the collector hood transition flange gasket Thread flanged nuts onto hold down bolts and finger tighten only Insert five 5 16 x 5 8 flanged bolts through holes in collector hood transition and collector hood assembly rear flange Thread on nuts and finger tighten only Tighten flue collector bolts and nuts Gradually tighten all bolts and nuts on flue collector assembly and boiler Tighten to between 30 and 35 inch pounds torque See WARNING upper right Alternate locations as you tighten the fasteners to ensure all parts are evenly drawn down with no gaps or distortion of parts Install damper and flue caps b Wipe item 5 Figure 10 flue damper flange surface with a clean rag Apply a few pieces of double faced tape to the flue damper flange Position flue collar gasket on damper and press firmly in place Align all holes before securing Position flue damper assembly against collector hood transition Insert a 10 x screw through the top center hole Lightly tighten to hold flue damper in position Insert remaining 10 screws into flue damper flange and lightly tighten Alternate from screw to screw and tighten all screws evenly and securely Install flue caps on flue collector top opening s using steps 5a through 5d DO NOT overtighten bolts in flue collector hood assembly Gasket material could e
27. e Weil McLain will provide replacement for the original cast iron section s upon the payment of a proportionate charge based on the time the boiler has been in service The proportionate charge will be equal 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 2096 15th year 2596 16th year 30 17th year 3596 18th year 4096 19th year 45 20th year 50 21st year 5596 22nd year 60 23rd year 65 24th year 70 25th year and beyond 75 Residential amp Commercial Cast Iron Boilers These warranties are subject to the condition that the boiler must have been installed by a heating contractor whose principal occupation is the sale and installation of plumbing heating and These warranties do not cover 1 Components that are part of the heating systems but were not furnished by Weil McLain as a part of the boiler 2 The workmanship of any installer of Weil McLain s boilers In addition this warranty does not assume any liability of any nature for unsatisfactory performance 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 Improper burner adjustments control settings care
28. e UE 10 7 Connect water boiler piping 14 8 Connect steam boiler piping cree 16 9 Jac lc a 20 10 Pipe tankless heaters eeLsee eere nennen 27 11 Install water boiler controls nn 28 12 Install steam boiler controls eere esee eese 29 13 Connect breeching and Venting system eese 31 14 install TU 32 15 Wiring and fuel piping e esee 32 16 Make final adjustments 32 17 Dimensions and 34 18 FYFYR o 36 Handling ceramic fiber and fiberglass materials 38 Hazard Definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels
29. e installing flue collector 1 See Figure 10 page 11 for general assembly of flue collector components See Figure 11 page 13 for the placement of flue collector hoods on each model Prepare mounting holes in boiler rear section b The boiler rear section has tapped holes for mounting rear flue collector component Remove any grit from threads inside tapped holes with clean rag Rear flue boilers only 1 12 See Figure 10 page 11 and Figure 11 page 13 2 Place collector hood transition on rear section a b C f Wipe item 10 Figure 10 collector hood transition flange surfaces with a clean rag Apply a few pieces of double faced tape on the collector hood transition flange Place the collector hood transition gasket item 8 Figure 10 on the collector hood transition flange Align holes in gasket with holes in flange Press gasket firmly in place Position collector hood transition on back of boiler rear section aligning collector hood transition flange holes with tapped holes in boiler rear section Insert a 5 16 x 5 8 flanged bolt through the bottom center hole and finger tighten to hold transition in place Install six remaining bolts securing collector hood transition to rear section Finger tighten only Place collector hood assembly on sections Carefully set collector hood assembly on top of section assembly Align slotted holes in collector hood flanges with the hol
30. eil McLain distributor The flue outlet for top flue models must be located as shown in this manual NOTICE Install collector hold down bolts 1 Figure 10 lower left Install a collector hold down bolt assembly at each section joint and on both sides of the boiler section assembly Set aside the flanged nuts for securing the collector assembly when it is ready 2 Each hold down bolt assembly consists of a 5 6 x 2 carriage bolt flat washer regular hex nut and a flanged nut as shown Prepare flue collector hood assembly 06 Make sure gaskets are intact not torn or otherwise damaged These conditions can cause possible flue gas leakage and carbon monoxide emissions resulting in severe personal injury or death WARNING The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 38 of this manual Failure to comply could result in severe personal injury 1 Stand flue collector hood front module item 4 on end as in Figure 8 left side Figure 8 Collector hood preparation Assemble cala mood end bo hood all recs j Assembe second hood i modula Models FAD and ge larger ony PILEI 2 Wipe all flanged surfaces with clean rag 3 Lay flue collector hood gasket item 2 on flange 4 Place flue collector end cap item 1 on gasket Align bolt holes Secure with seven 5 4 x 54 fl
31. gure 14 Cold water fill piping Cold water Check fill ME valve Water Manual meter isolation valve Pressure reducing valve ws condensate return when used Manual piping or condensate isolation receiver axi valve see Figure 18 page 18 Table 8 Steam boiler pipe size for typical 2 pipe steam systems Figure number Boiler model Hiser pipe size 31 number inches Equalizer i inches 380 3 15 480 4 580 4 a 680 3 3 780 4 4 16 880 4 4 ae 3 2 4 2 Vo 4 21 EN Based on ASHRAE Handbook recommendations allowing 1 2 oz pressure drop per 100 feet of pipe for dry return 2 Based on ASHRAE Handbook recommendations allowing 2 oz pressure drop per 100 feet of pipe at 3 5 psig Maintain minimum 24 height from waterline to header Part No 550 141 935 0602 e Installation Start Up Maintenance Parts 9 Connect steam boiler piping continued 2 Figure 15 Model 380 through 580 steam boiler piping NOTE System suppi mn wn minimum 24 inches between boiler water line and bottom d i of header nA E it of a PP O 5 Figure 16 Model 680 through 980 steam boiler piping NOTE minimum 24 inches between boiler water line and bottom of header Part No 550 141 935 0602 17 Waeil Mel ain ao Eor Li
32. hesive sealing rings silicone sealant 385 800 205 591 000 070 5 Heater cover plate carton 385 700 200 includes cover plate gasket studs nuts Tankless heater carton 590 921 917 includes tankless heater gasket studs nuts Heater gasket 590 317 550 8 Cleanout plate 450 030 928 Cleanout plate gasket 590 317 303 Burner mounting plate front refractory 412 burner opening 6 burner opening 591 000 072 Refractory retainer clip 562 650 105 Observation port assembly includes observation port assembly sealing rope screws 385 600 099 Sealing rope 590 735 140 Combustion chamber kit includes back refractory blanket bottom refractory blanket adhesive sealing rope sealing rope adhesive Flue damper assembly top flue boilers 8 10 12 Flue damper assembly rear flue boilers 8 10 12 385 700 220 425 800 090 425 800 091 425 800 092 425 800 096 425 800 097 425 800 098 not shown Flue collector hood hardware kit 385 800 215 includes flue collector hardware plus collector hood gasket kit below Flue collector hood end cap 463 000 003 36 1 1 1 1 2 14 4a 15 6 7 8 9 0 21 2 Collector hood gasket kit includes 2 flue collector hood gasket 3 circular collector hood gaskets 1 rectangular collector hood gasket flat stitched sealing rope double faced tape 385 800 218 Flue collector hood gasket Included in gasket kit Flue collector
33. hoods 450 020 300 450 020 301 450 020 302 450 020 303 450 020 304 Included with flue damper assembly Part No 550 141 935 0602 e Start Up Maintenance Parts e nstallation 18 Parts continued Part No 550 141 935 0602 Handling ceramic fiber and fiberglass materials WARNING This symbol is used in this addendum to indicate presence of hazards that can cause severe personal injury death or substantial property damage REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS WARNING The combustion chamber lining or base insulation panels in this product 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 requirements for cristobalite at the time this document 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
34. ings provided with boiler Do not make any other connection in that piping WARNING Pipe relief valve discharge through vertical piping to atmosphere Use rigid material Install drain pan elbow to drain drain to eliminate potential of severe freezing could occur Do not plug valve c Install water level controls and gauge glass as shown 1 Fittings for controls to be furnished by others 2 If water level control is not shown in Table 13 om o Bede page 30 locate casting mark on control and hook up fittings Nuisance shutdowns will occur 1 112 plug provided with boiler 2 By special request only Figure 28 Steam control locations Skim tapping Pipe skim piping to side of boiler Steam relief valve S 1 Primary water level control 4 1 Primary water level control Not used Secondary level control 1 Not used Secondary level control D1 NOTE D is tapped inte lop of section 4 NPT Supply C1 B 3 E1 Optional 1 A tapping i Back section note 2 Table 12 1 Optional inspection tapping Front section note 2 Table 12 i 3 NPT 2 Return 6217 Return Part No 550 141 935 0602 29 12 Install steam boiler controls continued Figure 29 Steam control siphon and fittings Secondary water level control Blowdown valve
35. inside section assembly and flue collector assembly for any light passing through unsealed areas Mark all unsealed areas Check unsealed areas for cause damaged gaskets sealing rope not in place or loose bolts or nuts Correct all conditions and repeat inspection procedure If unsealed areas cannot be eliminated discontinue the boiler installation Contact your Weil McLain distributor or sales office for assistance Part No 550 141 935 0602 e Installation Start Up Maintenance Parts 6 Install flue collector continued Figure 11 Flue collector components by model see Figure 10 page 11 for flue collector components not shown below gid fc 2 815 top here Cover an rear flue boilers w Locale top flue he m Cover on rear tue boilers 1180 el re _ 480 SEE LIT amp d 2 T Always caver this W um ume 1 d Locate top fue here Locate top flue hare Cover on rear flue boilers Cover on rear tive boilers i i Always cover this apening 580 mu EF a mm Locate top flue here Locate top flue here Cover rear lie boiler Cover rear flue boilers 980 Always cover this _ opening 5 d gar omma f 1 nA mm cttm L
36. ion Center boiler on foundation if used 4 Level boiler Shim under skid angles if necessary 5 Cut off cables Part No 550 141 935 0602 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 6 Inspect block assembly for disjointed sections Check gas tight seal of flue collector hood and cleanout plates Gas tight seal must be maintained to prevent possible flue 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 At unsealed areas check for damaged gaskets sealing rope not in place loose bolts or nuts d Correct all conditions and repeat step b If unsealed areas still exist contact your Weil McLain distributor or sales office before continuing installation 7 Proceed to Perform hydrostatic pressure test page 8 Table 2 number Ibs Ibs _ _ Lifting weights e ws Assemble block Sections are top heavy Unbolted sections may fall if not supported resulting in severe personal injury or death Install back refractory blanket Lay back section on floor with ports face up 2 Apply adhesive to blan
37. irborne fiber concentration requiring additional protection Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid M Eye Irrigate immediately BI Breathing Fresh air 38 Part No 550 141 935 0602 Propane boilers propane gas odorant WARNING 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 floor level Smell near the floor 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 gualified service technician particularly if flame 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 550 141 935 0602 39 Weil McLain Limited Warranty for Residential amp Commercial Cast Iron Boilers RESIDENTIAL WATER WARRANTY Limited Lifetime RESIDENTIAL STEAM WARRANTY Limited 10 Year COMMER
38. ket Press blanket against back target wall as shown in Figure 4 4 Using knife cut hole through blanket to expose observation port opening Prepare back section 1 Apply A continuous bead of sealing rope adhesive in sealing rope grooves See Figure 4 Do not get any adhesive on machined port surfaces 2 Place 2 sealing rope in groove Around curves grasp at 1 intervals and push together Do not stretch Do not pre cut rope Gas tight seal must be maintained to prevent possibility of flue gas leakage and carbon monoxide emissions causing severe personal injury or death 3 Remove any grit from port machined surfaces with clean rag Figure 4 Sealing rope installation sealing rope Cut off rope even with adgas 72 sealing ring Cut aff rope even _Sealing meth B 8 Woo EDD ODID ne 5 Dactanusaduecadosan lt Lu Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to system components can result causing substantial property damage 4 Place 7 3 sealing rings in appropriate port openings See Figure 4 If sealing ring slips out of groove stretch ring gently for several seconds then reposition in groove 5 Apply continuous bead of silicone sealant no larger than around entire outside edge of outer machined surface of port Refer to Figure 5 Do not apply silicone sealant on next to o
39. ks Stub vent height must be limited to prevent negative draft with 3 foot minimum stub vent height above roof See Figures 31 and 32 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 positive pressure at flue collar Minimum chimney height above roof 15 3 feet See Figures 33 and 34 Figure 31 Figure 32 Stub vent forced draft Stub vent forced draft single boiler multiple boilers Figure 33 Conventional chimney balanced draft with barometric draft control when required single boiler Figure 34 Conventional chimney balanced draft with barometric draft control when required multiple boilers Part No 550 141 935 0602 Jm a Construct metal breeching See Table 14 or Table 15 for minimum breeching diameter Select material type and thickness in compliance with local codes Conventional flue pipe should not be used asit could leak flue gases and carbon monoxide emissions through seams and joints resulting in severe personal injury or death Refer to ASHRAE Guide for chimney and breeching calculations and construction and lining Long horizontal breechings excessive number of tees and elbows or other obstructions restricting combustion gas flow can result in possibility of condensation flue gas leakage and
40. l after boiler is piped WARNING The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 38 of this manual Failure to comply could result in severe personal injury 2 Remove lag screws 2 in front 2 in rear from shipping rails 3 Remove boiler from skid Cables are already attached to block assembly See Table 2 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 6 Cut off cables 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 8 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 assembly See Table 2 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 posit
41. led gas tight to prevent possibility of flue gas leakage and carbon monoxide emissions resulting in severe personal injury or death 1 See Figure 7 Position two x 134 carriage bolts in cleanout opening Secure with washers and nuts 2 Place blanket insulation piece against cleanout plate 3 Mount cleanout plate over opening Secure with nuts and washers 4 Repeat steps 1 through 3 for remaining cleanout plates WARNING The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials instructions on page 38 of this manual Failure to comply could result in severe personal injury Part No 550 141 935 0602 Figure 7 Cleanout plate assembly Bolt amp washer Insulation Cleanout plate 4 Tn Washer E a Mut 4 1 Tw 5 iP a EM T gom ur Nut 8025 10 Install flue collector Flue collector assembly l Figure 10 page 11 shows flue collector components and locations Figure 11 page 13 shows collector hoods for all models Follow all instructions in this manual to ensure correct installation of the flue collector 2 Model 80 boilers are available with either rear flue or top flue Verify that you have the correct components for your application You can convert a Model 80 from rear to top or top to rear flue using a flue conversion kit available from your W
42. m side of blanket Press blanket into center bottom of sections section are installed At front section cut off blanket 2 Y from burner opening Discard unused blanket Prepare remaining sections 1 Follow Prepare intermediate section for remaining intermediate and front sections a Remove any grit from threads inside tapped holes with clean rag Part No 550 141 935 0602 Figure6 Sealing ring installation and port alignment Section Section DEN Alignment 2 Gockel 7 lug F XM 4 Silicone sealant El Matal lastomer to metal sealing ring Boiler model number Section arrangement all heaters must be on left side of boiler 680 WAS 780 W amp S 580 W amp S 980 W amp S F TI I TI I TI I I B EET TI TT THI TIE M80W 4 1 1 1 1 1 1 1 1 1808 4 F TI I TI I SI I TI I TI B 1280W 4 11 1 11 1 1 11 11 118 12805 4 F TI I TI I SI I I TI I TI E W water S steam F front B back I Intermediate TI tankless intermediate SI supply intermediate for steam boilers sections can be substituted for sections Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to system components can result causing substantial property damage b Checkeach section for proper sealing rope position before proceeding to next section Failure
43. ns Seperate burner manual provided with burner 1 Install all wiring in compliance with 2 Usepipejoint compound pipe dope resistant to corrosive action National Electrical Code ANSI NEPA 70 of fuel oil or liquified petroleum gases Apply sparingly to male Any additional national state or local codes threads of pipe joints Do not use any kind of pipe tape 2 Follow burner manual and wiring diagram found in burner 3 Oil piping use flare type fittings not compression type information packet DANGER Do not use compression or soldered fittings No safe 3 Use 14 ga wire for operating and safety circuit wiring repair can be made Severe personal injury death 4 Where burner motor voltage differs from control voltage supply or substantial property damage will result To fill water boilers proper voltage to each Size fused disconnect s and conductors per National Electrical Code ANSI NFPA 70 Propane boilers see WARNING on page 39 regarding propane gas odorant 16 Make final adjustments Adjust burner and damper assembly 1 Close manual air vents and drain cocks 2 Fill to correct system pressure Correct pressure will vary with each installation 3 Starting on lowest floor open air vents one at a time until water sguirts 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 read
44. ocate top flue here gt W 1 Locate top flue here Cover on rear fue boilers i Cover on rear flue boilers e d P 880 ye i Always cover this y n this mu opening 780 Part No 550 141 935 0602 13 7 Connect water boiler piping General water piping information System water supply and return piping should be installed and piping connections attached to boiler before erecting jacket or installing controls Donotpipein through supply and out through return This creates reverse water flow through boiler that must not be used When three way valves are used for temperature modulation install slow opening minimum 10 minute valves and boiler mixing pump to minimize potential of boiler thermal shock See W M Bulletin AE 8402 Install piping Install piping as shown in Figure 12 for single boilers For multiple boilers see Figure 13 page 15 Improperly piped systems or undersized piping can contribute to erratic boiler operation and possible boiler or system damage CAUTION 1 Connect supply and return piping a Size according to tables below 1 For unknown flow rates size piping per Table below using 20 F temperature rise through boiler 2 For known flow rates or higher flow rate through boiler size piping per Table below WARNING Flow at higher rates than shown in Table below for pipe size can dam
45. ombination float and thermostatic through 19 trap and drain to condensate receiver Part No 550 141 935 0602 19 9 Install jacket Before installina iacket The boiler contains ceramic fiber and 91 WARNING fiberglass materials Use care when 1 Packaged boilers handling these materials per instructions Install top jacket panels per instructions in this on page 38 of this manual Failure to manual comply could result in severe personal 2 Non packaged boilers 70 0 Follow the instructions in this section to install all jacket panels Make sure the following are completed before Remove jacket parts from cartons installing jacket 1 Locate jacket cartons Boiler hydrostatically pressure tested See page 8 Plugs for unused tappings installed See control tapping table page 28 or 29 Supply and return piping installed See pages 14 DA 19 95 dis Install support brackets and rails Cleanout plates flue collar and flue collector hood installed See pages 9 through 13 2 Remove jacket parts from cartons as needed Leave in cartons as long as possible to avoid damage 1 Place upper and lower support brackets over draw rods as shown in Figure 20 page 21 3 These parts must be on boiler plugs for unused tappings 2 Fasten securely with 5 nuts where shown e supply and return piping NOTICE Models 380 480 580 680 and 780 do not steam supply header require lower support brackets
46. p i EN a oe t a DANGER Hot water can scald Consumer Product Safety Commission and some states recommend domestic hot water temperature of 130 F or less When installing an automatic mixing valve selection and installation must comply with valve manufacturer s recommendations and instructions Water heated to a temperature suitable for clothes washing dish washing and other sanitizing needs will scald and cause injury Children elderly infirm or physically handicapped persons are more likely to be injured by hot water Never leave them unattended in or near a bathtub shower or sink Never allow small children to use a hot water faucet or draw their own bath If anyone using hot water in the building fits this description or if state laws or local codes require certain water temperatures at hot water faucets take special precautions Install automatic mixing valve set according to those standards Use lowest practical temperature setting Check water temperature immediately after first heating cycle and after any adjustment Part No 550 141 935 0602 27 11 Install water boiler controls Install controls Table 11 Water control tappings see Figure 27 1 Install furnished controls where shown in Table 11 and Figure 27 Tapping Size Water boilers with water level controls Fail ly install pi d wi Pn WARNING a 88 00 Probe
47. r under sealing ring Silicone sealant applied as specified above prevents unburned oil vapors from coming in contact with sealing ring Vapor contact can damage rings resulting in severe damage to boiler and substantial property damage 6 Position section upright on foundation if used and screw 3 pipe at least 22 long into 3 return tapping 7 Place a block under pipe to hold section upright Figure 5 Silicone sealant x Cut out Li observation DES DE port opening wc Back refractory o ed blanket apply adhesive to entire back side Silicone sealant applied per step 5 8002 6 Part No 550 141 935 0602 3 Assemble block continued Install intermediate sections Sections are top heavy Unbolted sections may fall if not supported resulting in severe personal injury or death Remove and discard 4 diameter shipping tie rods 2 Remove grit from port machined surfaces with clean rag Do not use petroleum based cleaning or sealing compounds 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 6 4 Install TI tankless intermediate and SI supply intermediate sections when used in order shown in Table 3 5 Draw sections together until metal to metal contact is made around ma
48. re 9 Flue collector sealing rope installation Extend 14 past edge at each end of rope Flatsstitehad sealing rope ls Double faced tape 60 4 I Part No 550 141 935 0602 e Installation Start Up Maintenance Parts 6 Install flue collector continued Figure 10 Flue collector components typical Model 880 collector configurations shown Flue collector components Flue collector end cap Hue collector hood gasket Flue collector hood rear Flue collector hood front d o Flue damper assembly top flue Flue cap top Circular flue collector gasket Rectangular flue collector gasket 9 Flue cap rear 10 Flue collector hood transition 11 Flanged 00115 556 x Sa 12 Flanged nuts Sa Top flue models 13 Sheet metal screw AB pan head Phillips 10 x 16 T AE 14 Flue damper assembly rear flue 5 Dowble faced tape applied flue collector afler cleaning Flat stitched sealing rope applied over tape Flue collector hold down bolt installation Flue collector hood Flanged nut Regular nut 9 5 Carriage bolt Boiler sections Fiat stitchad sealing ropa Section assembly typical Flue collector bolts to section assembly as shown Model 880 shown Part No 550 141 935 0602 H 6 Install flue collector continued Befor
49. rews at these eight 8 locations Lower left support bracket Lower right support bracket Apply 8045 Part No 5 550 141 002 21 9 Install jacket continued Install jacket side panels 1 Remove jacket side panels from cartons 2 Insert a plastic plug provided in jacket cartons in the 1 inch hole in the center of each of the jacket side panels 3 Before installing side panels square up the jacket support rails Place any of the jacket side panels on the rails as shown in Figure 21 Butt the side panel against the jacket front panel Push pull on the upper and lower rails until the fit up of the side panel front panel and rails 15 square 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 screws securing the upper and lower rails to the support brackets the screws securing the front and back panels to the rails 4 Apply all jacket side panels in the order shown in Figures 22 23 or 24 Remove jacket knockouts as required for tankless heaters 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 25 page 26 Remove knockouts for riser pipes or flue outlet using tin snips 2 Foldout ta
50. selecting boiler location 1 A floor could possibly become flooded 2 Non level conditions exist National codes where applicable 1 Check for nearby connections to a Fuelsupply b Electrical power Table1 Boiler foundation see Figure 3 c System water or steam piping d Venting systems see page 31 Boiler L Boiler Combustion and ventilation air supply see model Length model Length Provide combustion and ventilation air supply number inches number inches openings on page 4 2 Check area around boiler Remove any combustible materials gasoline and other flammable vapors and liquids WARNING Failure to keep boiler area clear and free of combustible materials gasoline and other flammable liguids and vapors can result in severe personal injury death and substantial property damage Figure 1 Boiler foundation Provide clearance around boiler w _ Provide minimum clearances to combustible materials M a 1 Singlewall vent pipe 18 inches 2 Doublewall vent pipe refer to vent pipe manufacturer s recommendations for vent pipe clearances 3 Boiler top 24 inches 4 Boiler front 48 inches Y 5 Boiler flue 9 inches E 1 6 Boiler rear 9 inches ie a 7 Boiler sides 6 inches E Boiler may be installed on combustible flooring bw on Nn al a 7 See pages 34 and
51. side wall or vertical ducts at least one sguare inch 4 000 Btuh boiler input b through horizontal ducts at least one sguare inch 2 000 Btuh boiler input c where ducts are used they should be same cross sectional area as free area of openings they are connected to d compensate for louver grille or screen blockage when calculating free air openings Refer to their manufacturer s instructions for size If unknown use wood louvers 20 25 free air metal louvers or grilles 60 75 free air screens not less than 14 inch mesh Lock louvers in open position or interlock with equipment to prove open before boiler operation When combustion and ventilation air enters through sidewall openings ensure openings comply with Figures 2 and 3 Figure2 Combustion and ventilation air openings Boiler room below grade Grating minimum 12 above average snow line Mote Size of areaway and grating to be equal to or greater than total louver area Areaway Boilar room floor Louver La Fa 5 zl Le Figure3 Combustion and ventilation air openings Boiler room partially or completely above grade 12 above average snow lina a Louver minimum 9 Duct size equal to total louver area Boiler Grade Bo41 Part No 550 141 935 0602 Set boiler in place For packaged boiler 1 Remove top jacket panels Set aside unti
52. to position sealing rope properly can cause boiler to not seal gas tight Gas tight seal prevents possible flue gas leakage and carbon monoxide emissions resulting in severe personal injury or death If using tankless heater TI sections 1 Install tankless heaters and gaskets or heater cover plates and gaskets Use 3 8 x 3 4 studs washers and nuts 4 Perform hydrostatic pressure test Prepare boiler and test 1 See pages 28 and 29 for tapping locations Install a Boiler drain not furnished b Water pressure gauge for test only Be sure gauge can handle test pressure see step 3 c Air vent in upper tapping K 2 Plugremaining tappings Do not pressure test with any control installed Damage to control can occur due CAUTION to overpressure 3 Fill boiler Vent all air Pressure test at least 10 minutes at a pressure not less than the following Steam boiler Between 45 and 55 psig Water boiler 11 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 WARNING 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 WARNING Leaks must be repaired at once Failure
53. transfer overheating cast iron and causing section failure For unusually hard water areas or low pH conditions less than 7 0 consult local water treatment company Freeze protection when used 1 Use antifreeze especially made for hydronic systems Inhibited propylene glycol is recommended WARNING Do not use automotive ethylene glycol or Insert screw through Damper undiluted antifreeze Severe personal ar tighten to injury or death can result ock damper a i i i T 2 5096 solution provides protection to about 30 F Skim steam boilers 3 Local codes may require back flow preventer or actual disconnect from city water supply NOTICE Clean all newly installed steam boilersto 4 Determine quantity according to system water content remove oil Failure to properly clean can Boiler water content is listed on page 34 Percent of result in violent water level fluctuations solution will affect sizing of heat distribution units water passing into steam mains or high circulator and expansion tank maintenance costs on strainers traps and vents Skim boiler only Do not clean old piping or leaks can occur WARNING Do not use petroleum based cleaning or sealing compounds in boiler system WARNING Boiler must be sealed gas tight to prevent Severe damage to system components can possible flue gas leakage and carbon 5 Follow antifreeze manufacturer s instructions Check boiler for gas tight seal result
54. type primary Float type primary Float type primary boiler controls can result in severe damage Probe type secondary Probe type secondary Float type secondary to boiler building and personnel and is DE AE UR a r Notused Secondary level control Notused Secondary level control 52 ESL EX EX 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 WARNING Relief valve discharge line must be piped using rigid material suitable for 375 F threaded one end near floor 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 cuttoff a Must be installed if boiler is located above radiation level b May be required on water boilers by certain state local or territorial codes or insurance companies c Install low water cutoff designed for water installations where shown in Table 11 and Figure 27 5209 3 Notes 1 1 plug provided with boiler 2 By special request only 4 If installation 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
55. uirements when piping multiple boilers Improperly piped systems or undersized piping can contribute to erratic boiler operation and possible boiler or system damage Piping system must be installed as shown using 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 CAUTION 1 Connect supply and return piping a See Table 8 1 Size condensate return piping by pump 2 Sizegravity condensate return same as equalizer J pipe size b Install system drain valve in lowest part of return piping close to boiler ASME size requirements are shown in Table 7 page 14 c Connectcold water fill piping as shown in Figure 14 Also shown are recommended valves and water meter if used Water meter will detect added makeup water indicating leaks in system 2 Condensate piping a Satisfactory operation of any steam heating system depends on adequate return of condensate to maintain steady water level b Avoid adding excessive amounts of raw make up water c Where condensate return is not adequate a low water cutoff with pump control condensate receiver and condensate boiler feed pump should be installed Refer to page 18 Figure 18 for piping and Table 9 for sizing 3 Multiple steam boiler piping a See page 19 Fi
56. xtrude causing possible flue gas leakage and carbon monoxide emissions resulting in severe personal injury or death Top flue boilers only 1 See Figure 10 page 11 and Figure 11 page 13 2 Place rear flue cap on rear section a b f Wipe item 9 Figure 10 rear flue cap gasket surface with a clean rag Apply a few pieces of double faced tape on the rear flue cap gasket surface Place the rectangular gasket item 8 Figure 10 on the flue cap aligning holes in gasket with holes in rear flue cap Press firmly in place Position rear flue cap on back of boiler rear section aligning rear flue cap holes with tapped holes in boiler rear section Insert a 5 16 x 5 8 flanged bolt through the bottom center hole and finger tighten to hold rear flue cap in place Install six remaining bolts securing rear flue cap to rear section Finger tighten only 3 Place collector hood assembly on sections b b C Carefully set collector hood assembly on top of section assembly Align slotted holes in collector hood flanges with the hold down bolts in the sections Place the collector hood assembly so its rear flange is against the rear flue cap gasket Thread flanged nuts onto hold down bolts and finger tighten only Insert five 5 16 x 5 8 flanged bolts through holes in rear flue cap and collector hood assembly rear flange Thread on nuts and finger tighten only 4 Tighten flue collector bolts and
57. y to be fired 2 Fill to normal waterline halfway up gauge glass 3 Recommend boiler water pH 7 0 to 8 5 22 l Lock open flue transition damper 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 2 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 3396 CO for No 2 fuel oil 0 smoke b 9 1096 CO natural gas CO in flue gas not to exceed 50 ppm 0 01 Adjust damper assembly Figure 35 page 33 to ensure 0 1 W C positive pressure at test opening Tighten screws to secure in position Plug test opening with 3 8 bolt provided with damper assembly 6 Adjust barometric draft control when used to design conditions N Repeat steps 4 through 6 Adjust as required Part No 550 141 935 0602 16 Make final adjustments continued Determine if water treatment is needed water boilers only WARNING Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to system components can result causing substantial property damage Figure 35 Flue damper assembly typical Test opening Continual make up water will reduce boiler life Minerals can build up in sections reducing heat
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