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Part No. 550-100-068/1009

for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners

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.

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.

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.

USER . . . .

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.

For additional
information, refer to . .

Burner
speciﬁcation and
data sheets

for burners pre-tested
with model 88 boilers

s)NSTALLATION

s3TARTUP

s-AINTENANCE

s0ARTS

Boiler Manual

Water & steam boilers – Series 2

88

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2
3
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Summary of Contents for 1088

Page 1: ...om the boiler jacket 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 USER 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 se...

Page 2: ...order can cause severe personal injury death or substantial property damage Do not use petroleum based cleaning or sealing components in boiler system Severe damage to system components can result causing sub stantial property damage 0ROPANE 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...

Page 3: ...TE BLOCK ASSEMBLY 12 ONNECT WATER BOILER PIPING 14 ONNECT STEAM BOILER PIPING 16 NSTALL JACKET 20 0IPE TANKLESS HEATERS 25 NSTALL WATER BOILER CONTROLS 26 NSTALL STEAM BOILER CONTROLS 27 ONNECT BREECHING AND VENTING SYSTEMS 29 NSTALL BURNER WIRING AND lLL SYSTEM 31 NSTALL FUEL PIPING 32 AKE lNAL ADJUSTMENTS 33 ANDLING CERAMIC lBER AND lBERGLASS MATERIALS 34 2ATINGS 35 IMENSIONS 36 0ARTS 38 Content...

Page 4: ...es OILER mUE s 9 inches OILER REAR s 9 inches OILER SIDES s 6 inches 3INGLE WALL VENT PIPE s 18 inches OUBLE WALL VENT PIPE s refer to vent pipe manufacturer s recommendations for vent pipe clearances Boiler may be installed on combustible ﬂooring 2 See 3 page 36 for boiler dimensions Flue pipe breeching clearances take precedence over jacket clearances Provide minimum clearances for servicing 4 E...

Page 5: ...he minimum volume must be calculated as speciﬁed in the standard NSIDE 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 OMBINING SPACES ON THE SAME STORY Each opening shall have a minimum free area of 1 in2 1000 Btuh 2200 mm2 kW of the total input rating of all appliances in the space but not less t...

Page 6: ...mbustion 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 Before installing boiler continued system the combustion air shall be supplied from outdoors at the minimum rate of 0 35 ft3 minute per 1000 Btuh 0 034 m3 min per kW for all appliances located within the sp...

Page 7: ... boiler Shim under skid angles if necessary 5 Cut off cables 6 Cables are not intended for long term usage Cables may corrode inside boiler weakening their lifting strength Fail ure to remove cables can result in severe personal injury death or substantial property damage Proceed to 7 Perform hydrostatic pressure test page 11 For block assembly Remove lag screws 2 in front 2 in rear from shipping ...

Page 8: ...ngs in appropriate port openings See 4 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 5 1 16 around entire outside edge of OUTER machined surface of port Refer to Figure 7 O NOT APPLY SILICONE SEALANT ON NEXT TO OR UNDER SEALING RING Silicone sealant applied as speciﬁed above pr...

Page 9: ...the jacket support brackets in place Draw rods should be torqued to a range of 90 to 100 ft lbs Do c not back off draw rods Metal to metal contact will be achieved around port openings d 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 e 032 check for rope extending from rope grooves dirt on port openings...

Page 10: ...088 W S 4 s 4 s s 4 s s 4 s s 4 s s 1188 W S 5 s 4 s s 4 s s 4 s s 4 s s 4 s 1288 W 5 s 4 s s 4 s s 4 s s 4 s s 4 s s 1288 S 4 s 4 s s 4 s s 3 s s 4 s s 4 s s 1388 W 6 s 4 s s 4 s s 4 s s 4 s s 4 s s 4 s 1388 S 6 s 4 s s 4 s s 4 s 3 s 4 s s 4 s s 4 s 1488 W 6 s 4 s s 4 s s 4 s s 4 s s 4 s s 4 s s 1488 S 5 s 4 s s 4 s s 4 s s 3 s s 4 s s 4 s s 1588 W 7 s 4 s s 4 s s 4 s s 4 s s 4 s s 4 s s 4 s 1588...

Page 11: ... found 4 Leaks must be repaired at once Failure to do so can dam age boiler resulting in substantial property damage Do not use petroleum based cleaning or sealing com pounds in boiler system Severe damage to system components can result causing substantial property damage Drain boiler and remove air vent boiler drain and gauge Remove 5 plugs from tappings that will be used for controls and access...

Page 12: ...pe in groove Overlap ends at least one b inch Install burner mounting plate with part number and the word c 50 positioned at top Use washers and nuts Install observation port assemblies on front and back sections Install front observation port assembly 1 Apply a 1 8 continuous bead of sealing rope adhesive in groove on observation port Position b 3 8 sealing rope in groove Secure assembly to secti...

Page 13: ...as shown in Fig ure 12 page 12 Install cleanout plates Cleanout plates must be installed gas tight to prevent possibility of flue gas leakage and carbon monox ide emissions resulting in severe personal injury or death See 1 Figure 13 Position two x 1 carriage bolts in cleanout opening be 2 tween the cleanout plate bosses as shown Secure with washers and nuts Place woven ﬁberglass gasket over carri...

Page 14: ... diameter before making any reduction For example a 4 inch return should not be reduced any closer to boiler return tap ping than 40 inches Install system blow off drain valve in lowest part of return d piping close to boiler ASME minimum size requirements are given in Figure 17 page 15 Install expansion tank 2 LOSED TYPE a connect to 1 tapping K see page 11 Use 1 NPT piping Any horizontal piping ...

Page 15: ...enda tions follow Size boiler pump GPM based on the following A 4EMP RISE PERATING LIMIT TEMP n 2ETURN WATER TEMP A 0 B OILER ROSS UTPUT TUH 4EMPERATURE RISE X Calculate only secondary boiler piping circuit resistance Al c low for head loss through the boiler equal to three 90 degree elbows of secondary pipe size Operate each boiler and its pump with a Weil McLain boiler d control panel Size secon...

Page 16: ...sate to maintain steady water level Avoid adding excessive amounts of raw make up water s Where condensate return is not adequate a low water cutoff s with pump control condensate receiver and condensate boiler feed pump should be installed See s Figure 21 for piping and Figure 22 for sizing Cold water fill piping IGURE Condensate piping to boiler IGURE Condensate receiver capacity required IGURE ...

Page 17: ...amage to system components and oxygen corrosion due to excess make up water ARTFORD LOOP PIPING FOR ALL STEAM BOILERS You must install the system supply pipe between the equalizer 1 elbow and the last boiler riser pipe connection to the header This assists in separating water from the steam as it turns upward into the steam supply pipe Locate the top of the Hartford loop return nipple at least 4 i...

Page 18: ... 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 Boiler water line all automatic wa...

Page 19: ...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 C of this manual Install stop valves per ASME code requirements D For pump return systems if using automatic s steam valves use only slow opening automatic valves Use a Weil McLain Boiler Control Sys tem such as a BCP pa...

Page 20: ...2 ends of the tie rods as shown 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 Place support brackets as listed below IGURE Boiler Upper brackets on sections Lower brackets on sections 488 2 3 None 588 2 4 None 688 2 5 None 788 2 6 None 8...

Page 21: ...s NSTALLATION s 3TART 5P s AINTENANCE s 0ARTS 21 Part No 550 100 068 1009 Installing jacket support brackets support channels and corners IGURE piping and other components omitted for clarity Install jacket continued ...

Page 22: ...the ﬁt up of s the side panel corner panel and channels is square Place a jacket top panel in position against the jacket front panel s 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 s brackets Tighten the screws securing the upper and lower rails to the s support brac...

Page 23: ... OILER MANUAL s NSTALLATION s 3TART 5P s AINTENANCE s 0ARTS 23 Part No 550 100 068 1009 Jacket side panel placement IGURE Install jacket continued ...

Page 24: ...Weil McLain 88 Water and steam boilers Series 2 for Gas Light Oil Gas Light Oil Fired Burners 24 Part No 550 100 068 1009 Jacket top panel placement IGURE Install jacket continued ...

Page 25: ...ycle and after any adjustment To pipe tankless heaters See 1 Figure 35 Size piping no smaller than heater inlet and out 2 let Automatic mixing valve must be installed See 3 Figure 35 Follow manufacturer s instructions to install Flow regulatingvalvemust beinstalled Sizeaccord 4 ing to continuous draw of heater See Figure 34 Follow manufacturer s instructions to install Operating control with small...

Page 26: ... is located above radiation level a May be required on water boilers by certain state local or ter b ritorial codes or insurance companies Install low water cutoff designed for water installations where c shown in Figure 36 and Figure 37 If installation is to comply with ASME installation requirements an 4 additional high temperature limit is needed Purchase and install in supply line between boil...

Page 27: ...ndensate Pipe near ﬂoor close to ﬂoor drain to elimi nate 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 Install water level controls and gauge glass per c Figure 38 Figure 39 and Figure 42 page 28 Fittings for controls to be furnished by others s If water level control is not shown in s Figure 41 page 28 lo...

Page 28: ...2 6 ONE 2 150 2 6 2 6 3 see Note 3 2 ONE 2 2 2 3 3 see Note 3 1 to 1 ONE Notes Other manufacturer s controls providing similar function may be used if properly 1 located and selected Use low water cut off function only Pump controller function must only be handled 2 by the primary control When pump control is used with feedwater tank install pump control on boiler and 3 make up water feeder on tan...

Page 29: ...re 45 and Figure 47 Construct metal breeching See 1 Figure 43 for minimum breeching diameter Select material type and thickness in compliance with local 2 codes Conventional ﬂue pipe should not be used as it 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 3 and cons...

Page 30: ...d steam boilers Series 2 for Gas Light Oil Gas Light Oil Fired Burners 30 Part No 550 100 068 1009 Connect breeching and venting systems Stub vent forced draft single boiler IGURE Stub vent forced draft multiple IGURE boilers ...

Page 31: ...ing 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 For unusually hard water areas or low pH conditions less than 7 0 consult local water treatment company Provide a water ...

Page 32: ... level Failuretocomplycouldresultinfuelleakageorﬁre caus ing potential severe personal injury death or substantial property damage A two pipe fuel oil piping system is required for all installations 1 Supply and return lines must enter tank from top extending to 2 within 4 to 6 inches from bottom of tank Use oil ﬁlter sized for fuel pump suction gear capacity 3 Install oil ﬁlter 4 Do not install ﬁ...

Page 33: ...er 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 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 1 A see Fig ure 38 page 27 Provide 2 skim piping from tappin...

Page 34: ...ber lining or base insulation from the boiler and place it in a plastic bag for disposal N Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thor oughly NIOSH stated First Aid N Eye Irrigate immediately N Breathing Fresh air REMOVAL OR INSTALLATION OF FIBERGLASS WOOL This product contains ﬁberglass jacket insulation and ceramic ﬁber materials in jacket insul...

Page 35: ... 464 3 709 12 000 2 880 3 225 110 8 86 0 83 4 85 7 83 1 46 32 1 735 0 75 16 339 8410 1588 33 0 4 809 3 996 12 925 3 102 3 475 119 4 85 9 83 3 85 7 83 1 49 85 1 854 0 76 16 362 9005 1688R 34 5 4 979 4 137 13 383 3 212 3 597 123 6 85 9 83 3 85 7 83 1 53 38 2 003 0 77 16 385 9525 1688 35 5 5 155 4 283 13 854 3 325 3 724 127 9 85 9 83 3 85 7 83 1 53 38 1 945 0 78 16 385 9525 1788 38 0 5 494 4 570 14 7...

Page 36: ...odel 3UPPLY RETURN TAPPINGS URNER LENGTHS IMENSION Supply tappings No size Return tappings No size Carlin Riello Power Flame Beckett Oil Beckett Gas Steam Water Steam Water 488R 2 5 2 5 1 6 1 6 21 33 31 21 29 488 2 5 2 5 1 6 1 6 21 33 31 21 30 588 2 5 2 5 1 6 1 6 21 33 31 21 30 688 2 5 2 5 1 6 1 6 21 33 34 22 30 788 2 5 2 5 1 6 1 6 21 33 34 22 30 888 2 5 2 5 1 6 1 6 21 49 34 22 30 988R 2 5 2 5 1 6...

Page 37: ... OILER MANUAL s NSTALLATION s 3TART 5P s AINTENANCE s 0ARTS 37 Part No 550 100 068 1009 Dimensions continued Dimensions see lettered dimensions on opposite page IGURE ...

Page 38: ...amper locking plate h 340 004 606 340 004 607 340 004 608 340 004 609 340 004 612 330 056 634 460 003 646 563 530 784 14 Cleanout plate 450 030 965 15 Woven ﬁberglass gasket for cleanout plate 590 317 305 16 18 Observation port assembly includes frame rope gasket plugs and sight glass Assembly a Sight glass only b Washer gasket for sight glass 2 c 56 x 156M x 56 inches 383 600 099 591 419 199 590 ...

Page 39: ... OILER MANUAL s NSTALLATION s 3TART 5P s AINTENANCE s 0ARTS 39 Part No 550 100 068 1009 Parts continued ...

Page 40: ...Weil McLain 88 Water and steam boilers Series 2 for Gas Light Oil Gas Light Oil Fired Burners 40 Part No 550 100 068 1009 ...

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