Weil-McLain 88 Series 2 Commercial Gas Oil Boiler Data Sheets

88
Water & steam boilers – Series 2
for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners
Boiler Manual
• Installation • Maintenance
• Startup
• Parts
For additional
information, refer to . .
Burner
specification and
data sheets
for burners pre-tested
with model 88 boilers
This manual must only be used by a qualified
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.
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 recommend regular service by a qualified service technician,
at least annually.
Part No. 550-100-068/1018
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
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 important information concerning the life of the product.
Indicates presence of hazards that will cause severe personal injury,
death or substantial property damage if ignored.
Indicates presence of hazards that can cause severe personal injury,
death or substantial property damage if ignored.
Indicates presence of hazards that will or can cause minor personal
injury, death or substantial property damage if ignored.
Indicates special instructions on installation, operation or maintenance
that are important but not related to personal injury.
Read before proceeding:
Read all instructions before installing. Failure to follow all instructions
in proper 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 substantial property damage.
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 qualified 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.
2
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Contents
Before installing boiler . . . . . . . . . . . . . . . . . . . . . .4
Set boiler in place . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembling the block . . . . . . . . . . . . . . . . . . . . . .8
Perform hydrostatic pressure test . . . . . . . . . . . . . . 11
Complete block assembly . . . . . . . . . . . . . . . . . . . 12
Connect water boiler piping . . . . . . . . . . . . . . . . . . 14
Connect steam boiler piping . . . . . . . . . . . . . . . . . 16
Install jacket . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pipe tankless heaters . . . . . . . . . . . . . . . . . . . . . 25
Install water boiler controls . . . . . . . . . . . . . . . . . . 26
Install steam boiler controls . . . . . . . . . . . . . . . . . . 27
Connect breeching and venting systems . . . . . . . . . . 29
Install burner & wiring and fill system . . . . . . . . . . . . 31
Install fuel piping . . . . . . . . . . . . . . . . . . . . . . . . 32
Make final adjustments . . . . . . . . . . . . . . . . . . . . 33
Handling ceramic fiber and fiberglass materials���������������������34
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Part No. 550-100-068/1018
3
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Before installing boiler
Installation must comply with —
Figure 1
Boiler foundation, when required
Figure 2
Boiler foundation (see Figure 1)
1. State, provincial and local plumbing, heating and electrical
codes.
2. Regulations of servicing utilities.
3. ASME Section IV, Low Pressure Boiler and Pressure Vessel Code.
4. National Fuel Gas Code, ANSI/NFPA 54 - latest edition, when
applicable.
5. National codes where applicable.
Before selecting boiler location
1. Check for nearby connections to:
a. Fuel supply.
b. Electrical power.
c. System water or steam piping.
d. Venting systems - see page 29.
e. Combustion and ventilation air supply — see page 5.
2. Check area around boiler. Remove any combustible materials,
gasoline and other flammable vapors and liquids.
Failure to keep boiler area clear and free of combustible
materials, gasoline and other flammable liquids and
vapors can result in severe personal injury, death and
substantial property damage.
Boiler model
number
Length, L, minimum
(inches)
488
33
588
41
688
49
788
57
888
65
988
73
1088
81
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.
1188
89
1288
97
1388
105
1488
113
Lay a foundation, if needed
1588
121
1. Floor construction and condition must be suitable for weight of
boiler when filled with water. See page 35 for approximate boiler
operating weight.
2. A level concrete or brick foundation, constructed per Figure 1 and
Figure 2 is required when:
a. A floor could possibly become flooded.
b. Non-level conditions exist.
1688
129
1788
137
1888
145
Provide clearance around boiler
1. Provide minimum clearances to combustible materials:
24 inches.
• Boiler top —
• Boiler front — 48 inches.
9 inches.
• Boiler flue —
9 inches.
• Boiler rear —
6 inches.
• Boiler sides —
• 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 flooring.
3. See page 36 for boiler dimensions.
Flue pipe/breeching clearances take precedence over
jacket clearances.
4
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Before installing boiler (continued)
Combustion and ventilation air openings
Figure 3
Combustion and ventilation air openings
— Boiler room below grade
Figure 4
Combustion and ventilation air openings
— Boiler room partially or completely
above grade
Adequate 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.
Do not install an exhaust fan in boiler room. Incorrect burner operation can result.
When combustion and ventilation air enters
through side wall openings, ensure that the openings 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 National Fuel Gas Code, ANSI/NFPA 54- latest
edition). The following information is taken from
ANSI/NFPA 54- latest edition. 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- latest edition.
Exception: 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 in2/1000 Btuh (2200 mm2/kW) of the total
input rating of all appliances in the space but not less than 100 in2
(0.06 m2). 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
in different stories shall be considered as communicating spaces where
such spaces are connected by one or more openings in doors or floors
having a total minimum free area of 2 in2/1000 Btuh (4400 mm2/kW)
of total input rating of all appliances.
Part No. 550-100-068/1018
Combustion air openings to
outside
Outdoor combustion air can be taken through permanent 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 enclosure shall be provided. The openings shall communicate
directly, or by ducts, with the outdoors or spaces that
5
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Before installing boiler (continued)
freely communicate with the outdoors, as follows:
• 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 in2/4000 Btuh
(550 mm2/kW) of total input rating of all appliances in the
enclosure.
• Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of
1 in2/2000 Btuh (1100 mm2/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 in2/3000 Btu/hr (700 mm2 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. Follow all requirements
of the standard to determine the minimum volume of interior spaces
and to calculate minimum sizes of openings.
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 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 interlocked to the mechanical air supply system to
prevent main burner operation where the mechanical air supply system is not in operation.
• Where combustion air is provided by the building’s mechanical ventilation system, the system
shall provide the specified combustion air rate
in addition to the required ventilation air.
Louvers, Grilles, and Screens.
The required size of openings for combustion, ventilation, 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 required to provide the free area specified.
Where the louver 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 ¼ inch mesh.
Engineered Installations
Motorized louvers
Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air and shall he approved
by the authority having jurisdiction.
Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior
to main burner ignition and during main burner operation. 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.
Mechanical Combustion Air Supply
Where all combustion air is provided by a mechanical air supply
6
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Set boiler in place
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.
Cables used for lifting are NOT provided by Weil-McLain.
Figure 5
Boiler
model
number
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.
2. Remove lag screws (2 in front, 2 in rear) from shipping rails.
3. Remove boiler from skid. See Figure 5 for lifting weight.
Approximate
lifting
weight
Minimum
sling length —
(pounds)
(from crane hook to
boiler lifting lugs)
488
2928
2' 6"
588
3490
3' 0"
688
4152
4' 0"
788
4714
4' 6"
888
5276
5' 0"
988
5838
6' 0"
For packaged boiler:
1. Remove top jacket panels. Set aside until after boiler is piped.
Section assembly lifting weights
•
Using crane — hook middle of each cable to eye of crane.
1088
6400
6' 6"
•
Using hoist — hook middle of each cable to hoist. Raise boiler off
skid. Use pipe rollers under skid angles to roll boiler.
1188
7062
7' 0"
1288
7624
8' 0"
5. Level boiler. Shim under skid angles, if necessary.
1388
8186
8' 6"
6. Cut off cables.
1488
8748
9' 0"
1588
9310
10' 0"
1688
9872
10' 6"
1788
10,584
11' 0"
1888
11,146
12' 0"
4. Place boiler in final position. Center boiler on foundation, if used.
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.
Gas tight seal must be maintained to prevent possible flue gas leakage and carbon
monoxide emissions, resulting in severe
personal injury or death.
2. Remove boiler from skid. 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.
4. Level boiler. Shim under skid angles, if necessary.
5. 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.
6. Inspect block assembly for disjointed sections. Check gas-tight seal of
flue collector hood and clean out plates.
Part No. 550-100-068/1018
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.
• 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 11.
7
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Assembling the block
Sections are top heavy. Unbolted sections
may fall if not supported, resulting in severe
personal injury or death.
Figure 6
Sealing rope installation
Prepare and position back section
1. Apply 1/8" continuous bead of sealing rope adhesive in sealing rope grooves. See Figure 6. Do not get any adhesive on
machined port surfaces.
2. Place ½" 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. Cut rope as each section
is completed.
3. Remove any 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.
4. 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.
5. Apply continuous bead of silicone sealant no larger than 1/16"
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.
Figure 7
Silicone sealant
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. Hoist back section upright. Then temporarily screw a 6-inch
threaded pipe at least 36 inches long into the lower (return)
tapping.
7. Hoist the section and put into position.
8. Place a block under the 6-inch pipe to hold the back section
upright and plumb.
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 sections have been installed, and the assembly is stable.
10. Install intermediate sections as described on the following
page.
8
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
Assembling the block
• Maintenance
• Parts
(continued)
Sections are top heavy. Unbolted sections may
fall if not supported, resulting in severe personal
injury or death.
Figure 8
Sealing ring installation and port alignment
Install intermediate sections
1. Remove and discard 3/8" 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 8.
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.
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. Oil threads 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.
6. Repeat steps 1-5.
7. Check each section for proper sealing rope position
before proceeding to next section.
Failure 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.
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.
c. Draw rods should be torqued to a range of 100 to 120 ft-lbs.
Do not back off draw rods.
d. 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.
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.
Part No. 550-100-068/1018
8. Install remaining intermediate sections and front section
using the same procedure.
If using tankless heater (TI) sections
•
Install tankless heaters and gaskets or heater cover plates
and gaskets. Use 3/8" x 3/4" studs, washers and nuts.
9
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Assembling the block
Figure 9
Section arrangement
Max.
Boiler model
number
number
10
(continued)
Section arrangement
(all heaters must be on left side of boiler)
W = water
S = steam
of
tankless
heaters
488 W&S
1
F • TI • I • B
588 W&S
2
F • TI • I • TI • B
688 W&S
2
F • TI • I • TI • I • B
788 W&S
3
F • TI • I • TI • I • TI • B
888 W&S
3
F • TI • I • TI • I • TI • I • B
988 W&S
4
F • TI • I • TI • I • TI • I • TI • B
1088 W&S
4
F • TI • I • TI • I • TI • I • TI • I • B
1188 W&S
5
F • TI • I • TI • I • TI • I • TI • I • TI • B
1288 W
5
F • TI • I • TI • I • TI • I • TI • I • TI • I • B
1288 S
4
F • TI • I • TI • I • SI • I • TI • I • TI • I • B
1388 W
6
F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • B
1388 S
6
F • TI • I • TI • I • TI • SI • TI • I • TI • I • TI • B
1488 W
6
F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • B
1488 S
5
F • TI • I • TI • I • TI • I • SI • I • TI • I • TI • I • B
1588 W
7
F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • B
1588 S
7
F • TI • I • TI • I • TI • I • TI • SI • TI • I • TI • I • TI • B
1688 W
7
F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • B
1688 S
7
F • TI • I • TI • I • TI • SI • TI • I • TI • I • TI • I • TI • I • B
1788 W
8
F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • B
1788 S
8
F • TI • I • TI • SI • TI • I • TI • I • TI • SI • TI • I • TI • I • TI • B
1888 W
8
F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • B
1888 S
6
F • TI • I • TI • I • SI • I • TI • I • TI • I • SI • I • TI • I • TI • I • B
F = front / B = back / I = Intermediate
TI = tankless intermediate SI = supply intermediate (steam only)
"I" can be substituted for "TI" sections
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Perform hydrostatic pressure test
Prepare boiler and test:
1. See Figure 10 and Figure 11 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. Plug remaining tappings.
Figure 11 Boiler tappings
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 not
less than the following:
a. Steam boiler: Between 45 and 55 psig.
b. Water boiler: 1½ times maximum allowable working pressure (MAWP) stamped on the boiler nameplate, located on boiler
jacket front panel.
Do not exceed above test pressures by more than 10 psig.
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.
Leaks must be repaired at once. Failure to do so can damage
boiler, resulting in substantial property damage.
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.
Figure 10 Boiler tapping locations and sizes (see Figure 11)
Location
Size
A
2"
B
L
C1 & C2
C1
2"
1"
1"
D1 & D2
1"
Steam
Steam relief valve and/or
Skim tapping
Steam relief valve
Secondary probe LWCO
Low water cut-offs
—
Water
E1 & E2
½"
Gauge glass
High limit
Manual reset limit
Water relief valve
Not used — Plug
Alternate low water cut-offs
Combination high and low
limit control
Firing rate temperature
control (when used)
Low water cut-offs
—
F1 & F2
C\,"
Try cock tappings
—
G
¾"
Combination pressure–temperature
gauge
H
¾"
K
1"
Pressure limit control,
Pressure operating control and
pressure gauge,
Firing rate pressure control
(when used)
Boiler drain (see Figure 18,
page 15, for system blow-off
(drain) valve locations and sizes
—
M
2"
Blowdown/drain
Alternate low water cut-offs
Part No. 550-100-068/1018
Boiler drain
Piping to compression tank or
automatic air vent
—
11
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Complete block assembly
Install burner mounting plate on front
section
Figure 12 Combustion chamber blanket location
1. Install four (4) ½" x 3½" studs to secure burner mounting
plate to section:
a. Thread and lock together two (2) nuts on rounded end
of stud. Thread flat end of stud into one of four (4) holes
located around opening.
b. Remove nuts.
c. Repeat steps a and b for remaining studs.
2. Install burner mounting plate:
a. Apply 1/8" continuous bead of sealing rope adhesive in
groove around opening in section.
b. Position ½" sealing rope in groove. Overlap ends at least
one inch.
c. Install burner mounting plate with part number and the
word, "UP," positioned at top. Use ½" washers and nuts.
Install observation port assemblies on
front and back sections
1. Install front observation port assembly:
a. Apply 1/8" continuous bead of sealing rope adhesive in
groove on observation port.
b. Position 3/8" sealing rope in groove.
c. Secure assembly to section. Use 10-32 x ¾" truss-head
screws.
2. Repeat above steps for back observation port assembly.
Install the combustion chamber blanket
insulation
The 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. Remove any debris from inside the combustion chamber,
leaving the combustion chamber as clean as possible.
2. Apply waterglass to the bottom and left side of the combustion chamber (see drawing below for dimensions). Starting
from the rear of the combustion chamber, unroll the combustion chamber blanket covering the bottom and left side
as you work your way to the front of the boiler.
3. Cut off combustion chamber blanket 2-1/2” back from burner
opening. Discard cut off piece.
4. Apply 1/8” continuous bead of sealing rope adhesive in sealing rope groove.
5. Position rope in groove, overlapping ends at least 1”. Cut off
excess rope and discard.
12
Insert HXT-bars
1. See Figure 13, page 13.
2. Flue HXT-bars are identified by painted ends. They must
be inserted as shown, with the HXT-bars in the sequence:
•
Top position
•
red-tipped, HXT-bar 24 inches long — place on the
top row of pins.
•
Middle position
•
white-tipped HXT-bar, 26 inches long — place on
the first row of pins below the top clean-out plate
boss.
•
Bottom position
•
blue-tipped HXT-bar, 34 inches long — place on
the first row of pins below the bottom clean out
plate boss.
DO NOT insert a bottom HXT-bar into the opening between the FRONT section and the first
intermediate section.
3. To remove flue HXT-bars when required to clean the boiler
flueways, grab the end of each HXT-bar with pliers and
pull straight out. Clean HXT-bars and replace as shown in
Figure 13, page 13.
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Complete block assembly (continued)
Figure 13 Insert HXT-bars through clean out openings as shown below (omit the bottom, blue-tipped, HXT-bar in the opening
between the front section and the first intermediate section)
Install clean out plates
Figure 14 Clean out plate assembly
Clean out plates must be installed gas-tight to
prevent possibility of flue gas leakage and carbon
monoxide emissions, resulting in severe personal
injury or death.
1. See Figure 14.
2. Position two (2) ¼" x 1¾" carriage bolts in clean out opening, between the clean out plate bosses, as shown. Secure
with washers and nuts.
3. Place woven fiberglass gasket over carriage bolts.
4. Mount clean out plate over opening. Secure with nuts and
washers.
5. Repeat steps 1 through 3 for remaining clean out plates.
Install draft hood collar
1. Install 1/8" continuous bead of sealing rope adhesive in groove
on draft hood collar.
2. Position ½" sealing rope in groove. Overlap ends of rope at
least 1 inch.
3. Mount collar over flueway outlet on back section. Secure with
½ x 1½" hex head cap screws and washers.
Part No. 550-100-068/1018
13
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Connect water boiler piping
General water piping information
Figure 15 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. Do not pipe in through supply and out through return. This creates
reverse water flow through boiler that must not be used.
3. When installing in a system in which return water temperature can
drop below 140°F, apply the by-pass piping with by-pass pump as
shown in .
Install piping
Install piping as shown in Figure 15, page 14 and Figure 19, page 15
(if applicable) for single boilers. For multiple boilers, see
Figure 20, page 15.
Improperly piped systems or undersized piping can
contribute to erratic boiler operation and possible boiler
or system damage.
1. Connect supply and return piping:
a. Size according to tables below.
•
For known flow rates or higher flow rate (less than 20°F
temperature rise) through boiler, see Figure 16.
•
For unknown flow rates, size piping per Figure 18, page 15,
using 20°F temperature rise through boiler.
Flow at higher rates than shown in the tables in this
manual for given pipe sizes can damage the boiler, causing substantial property damage.
b. Locate circulator in supply piping.
c. For return 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
given in Figure 18, page 15.
2. Install expansion tank:
a. Closed type – connect to 1" tapping "K" (see page 11). Use
1" NPT 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. Figure 15
shows typical piping when using a closed type tank. Connect
to the same location as the expansion tank connects to the
system when using a diaphragm type tank.
d. Also shown are recommended valves and water meter, when
used. Water meter will detect added make-up water, indicating
leaks in system.
14
Figure 16 Recommended minimum pipe sizes for
known flow rates (note 1)
Water flow rate
GPM
Supply pipe size
A
Return pipe size
B
Up to 35
2"
2"
36–50
2½"
2½"
51–77
3"
3"
78–142
4"
4"
143–237
5"
5"
238–404
6" (note 2)
6"
Note 1
Note 2
High temperature rise through boiler is permissible when boiler
piping connections are sized per this table. Intermittent
flow at high velocities may damage any boiler.
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 ¼ PSI. For smaller boilers, the
pressure drop will be less.
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Connect water boiler piping (continued)
Figure 17 Recommended minimum pipe sizes when flow rate is
not known (see Figure 15, page 14) (note 1)
Boiler
model
Supply pipe size
A
488
3"
3"
4"
4"
888 – 1188
5"
5"
1288 – 1888
6" (note 2)
6" (note 2)
Note 2
140°F
Return pipe size
B
588 – 788
Note 1
Figure 19 By-pass piping for return water less than
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 16, 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 ¼ PSI. For smaller boilers, the pressure
drop will be less.
By-pass circulator sizing:
1. Size system circulator as required. Determine GPM
and head requirements.
2. Provide a by-pass circulator for EACH boiler. The flow
rate for each by-pass circulator will be:
Flow = ¼ x (System circulator GPM) ÷ (# of boilers)
3. All circulators must run at the same time.
Figure 18 ASME blowoff/drain valve size
Boiler
model
Minimum blow-off
valve size
488 – 588
1"
688 – 1088
1¼"
1188 – 1888
1½"
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 GPM = ¼ 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 adequate.
Piping multiple boilers
1. See Figure 19. (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 19 and boiler pump sizing recommendations follow:
Figure 20 Multiple water boiler piping
A Size boiler pump GPM based on the following:
a. Temp rise = Operating limit temp – Return water temp
Boiler Gross Output, Btuh
b. GPM =
Temperature rise x 500
c. Calculate only secondary (boiler) piping circuit resistance. Allow for head loss through the boiler equal to three 90 degree
elbows of secondary pipe size.
d. Operate each boiler and its pump with a Weil-McLain boiler
control panel.
e. Size secondary (boiler) circuit piping using the flow rate ranges
given in Figure 18, page 15.
B Primary pump GPM and head calculation should not include
secondary boiler circuits. Primary pump can operate continuously
during heating season.
C Connection to primary circuit — Space 12" maximum or as close
as practical.
D Check valve.
E Hand valve.
Part No. 550-100-068/1018
15
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Connect steam boiler piping
General steam piping information:
Figure 21 Cold water fill piping
1. Hartford loop piping arrangement and wet return are required for
steam boilers. Use the Hartford loop for both pumped-return and
gravity-return systems.
2. Maintain 24-inch minimum from waterline to bottom of header
(63" from bottom of section).
3. When using condensate receiver, feed pump must be energized by
boiler-mounted pump controller.
4. Install piping:
a. Install piping as shown on page 17 through page 18 for single
boilers. See page 19 for additional requirements when piping
multiple boilers.
b. Return pipe sizing.
• Pumped return — Size return piping by pump.
• Gravity return — Size gravity return same as Hartford loop
equalizer pipe size.
c. Drain valve — Install system drain valve in lowest part of return
piping close to boiler. See Figure 18, page 15, for sizing.
d. Cold water fill piping — Connect cold water fill piping as shown in
Figure 21. Also shown are recommended valves and water meter,
if used. Water meter will detect added makeup water, indicating
leaks in system.
e. Condensate return piping:
• Satisfactory operation of any steam heating system depends on
adequate return of condensate to maintain steady water level.
• Avoid adding excessive amounts of raw make-up water.
• Where condensate return is not adequate, a low water cutoff
with pump control, condensate receiver, and condensate boiler
feed pump should be installed.
• See Figure 22 for piping and Figure 23 for sizing.
Figure 22 Condensate piping to boiler
Figure 23 Condensate receiver capacity required
Boiler
model
number
AHRI gross output
(lbs steam
per hour)
Gallons
condensate
per hour
15-minute boiler
operation
488
8 10
794
1084
1358
1632
1904
2170
1991
2452
2304
2724
3000
3270
3550
3820
4090
3980
4370
4640
97
95
130
163
195
228
261
239
294
277
327
360
392
426
458
490
478
524
557
29
28
39
49
59
68
78
72
88
83
98
108
117
127
137
147
143
157
167
488R
588
688
788
888
988
988R
1088
1088R
1188
1288
1388
1488
1588
1688
1688R
1788
1888
Minimum condensate receiver capacity (gallons) (Note 1)
Recommended condensate
feed pump capacity
30-minute boiler 45-minute boiler 60-minute boiler
GPM at 15 PSI
operation
operation
operation
58
57
78
98
117
137
157
145
176
166
196
216
235
255
274
294
287
314
334
87
85
117
147
176
205
235
217
265
249
294
324
353
383
412
441
430
471
501
116
114
156
196
234
273
313
289
353
332
392
432
470
511
550
588
574
629
668
3.2
3.1
4.3
5.4
6.5
7.6
8.7
8.0
9.8
9.2
10.9
12.0
13.1
14.2
15.3
16.4
15.9
14.5
18.6
Note 1 — Maximum time to when condensate returns to boiler — the longer the time for condensate to return, the larger the receiver must be.
16
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Connect steam boiler piping (continued)
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.
Figure 24 Model 488 through 688 steam (1 riser)
Riser
Minimum height of header above water line must be
24 inches
A 1
10 24” m
in
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 serious damage
to system components and oxygen corrosion due to excess
make-up water.
lizer J
6
8
4” from
to
loop clos p of Har tford
e
water lin nipple to
e
BOILER
RETURN
49”
11
Back
of
boiler
Hartford loop piping for all steam boilers
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 the steam
supply pipe.
2. Locate the top of the Hartford loop return nipple at least 4 inches below
the water line, as shown.
7
8810
Model
488
588 & 688
Pipe
Dimensions
Riser A
4"
5"
Header H
4"
5"
Equalizer J
2½"
2½"
Figure 25 Model 788 through 1188 steam (2 risers required)
(Figure 24 through Figure 27)
Offset m
us
of boile t be past side
r for retu
rn offset
.
1
Part No. 550-100-068/1018
5
Equa
9
line
t
Wa er
Near boiler piping must be as shown in Figure 25. The near
boiler pipe may be welded between the needed threaded
joints. A threaded joint may not be replaced by a welded
joint. The steam supply must be supported to allow movement.
Riser pipes (one for each supply intermediate section)
2 Horizontal pipes needed to offset the
header to allow for expansion and
contraction of the header
3 Steam supply must be located between
last riser connection and equalizer
elbow
4 Equalizer elbow — full size or reducing
5 Equalizer pipe
6 Close nipple at Hartford loop tee to
reduce water hammer potential
7 Condensate return line (gravity or
pumped)
8 Minimum 4 inches between water line
and top of Hartford loop return nipple
9 Boiler water line — all automatic
water level controls must be set to
maintain this level
10 Minimum 24 inches between water
line and bottom of header
11 Offset tee
er H
Head
4
Steam boiler piping guidelines
Drawing legend & notes
3
Offset m
us
of boile t be past side
r for retu
rn offset
.
2
2
2 threaded joints
rotate horizontally
STEAM SUPPLY
3
er H
Head
Riser
1
4
A
Riser
1
B
10 24” min
lizer J
Equa
line
Water 9
2 threaded joints
rotate horizontally
5
8
6
4” from
to
loop clos p of Har tford
e
water lin nipple to
e
49”
BOILER
RETURN
11
Back
of
boiler
7
8811
Pipe
Dimensions
Model
788
888
988 & 1088
1188
Riser A
4"
5"
5"
5"
Riser B
4"
5"
5"
5"
Header H
6"
6"
8"
8"
Equalizer J
2½"
2½"
2½"
4"
2 threaded joints
rotate vertically
17
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Connect steam boiler piping (continued)
Figure 26 Model 1288 through 1888 steam (3 or 4 risers required)
3
2
er H
Head
Riser
A 1
Riser
1
B
Riser
4
D
Riser
C 1
5
10 24” mi
n
line
Water 9
lizer J
Equa
8
6
4” from
to
loop clo p of Hartford
se
water lin nipple to
e
49”
BOILER
RETURN
Back
of
boiler
11
8812
7
Pipe Dimensions
Model
1288 – 1488
1588 – 1688
1788 – 1888
Riser A
5"
5"
5"
Riser B
5"
5"
5"
Riser C
5"
5"
5"
Riser D
NA
NA
5"
Header H
8"
10"
10"
Equalizer J
4"
4"
4"
Drawing legend & notes
(Figure 24 through Figure 27)
1
2
3
4
5
6
7
8
9
10
11
18
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
Boiler water line — all automatic water level controls must be set to maintain this level
Minimum 24 inches between water line and bottom of header
Offset tee
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Connect steam boiler piping (continued)
Figure 27 Multiple Steam Boiler Piping Gravity Condensate Return
tem
See page 18 for numbered
circle references.
s
To sy
F
D
D
E
G
B
1
Riser
B
1
Riser
Wat
C
10 24” min
49”
Wa
Back
of
boiler
8
4” from
to
loop clo p of Hartford
se
water lin nipple to
e
Back
of
boiler
10 24” min
9
er line
9
e
n
i
l
r
te
49”
C
BOILER
RETURN
8
4” from
to
loop clo p of Hartford
se
water lin nipple to
e
BOILER
RETURN
11
A
11
A
8814
A Pipe as shown for gravity return systems, connecting point A
to the wet gravity return.
• For pumped-return systems, install boiler water level
control on each boiler with body mark at level indicated
in Figure 44, 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.
B For pumped-return systems, install a combination float and
thermostatic trap on each boiler to prevent flooding of one
boiler while other boiler is firing. Install trap in skim tapping
(see Figure 41, 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.
C Install boiler piping as shown in the preceding pages of this
manual.
Part No. 550-100-068/1018
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 System (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:
•
•
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.
Pumped-return: Use combination float and thermostatic
trap and drain to condensate receiver.
19
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Install jacket
Before installing jacket
Figure 28 Place support brackets as listed below
The 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. Clean out 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
3. These parts must be off boiler:
a. Water or steam gauge
b. Limit control and low water cutoff
c. Gauge glass and gauge glass cocks, tri-cocks
d. Drain cock
Boiler
Upper brackets on
sections:
Lower brackets
on sections:
488
588
688
788
888
988
1088
1188
1288
1388
1488
1588
1688
1788
1888
2, 3
2, 4
2, 5
2, 6
3, 6
2, 5, 8
3, 6, 9
3, 6, 9
3, 7, 10
3, 7, 11
3, 7, 10, 13
2, 5, 8, 11, 14
2, 5, 9, 12, 15
2, 5, 9, 13, 16
2, 6, 10, 14, 17
None
None
None
None
None
None
6
6
7
7
7
8
9
9
10
3. Attach the upper channels to the upper supports as
shown in callouts , and , Figure 30, page 21. Use
two #10 x ½" screws at each bracket. Models 988 and
larger have two-piece channels.
•
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 & hex nuts
BKT
Jacket side support channels, upper & lower
included in TRM/CHNL boxes
Jacket front/rear support channels, upper & lower
COM
Jacket front panel
PNL-F
Jacket back panel
PNL-B
Jacket side and top panels
L / R /T
Jacket corners
CRNR
Jacket trim
TRM/CHNL
Install support brackets/channels
1. Place upper and lower support brackets over draw rods as shown
in Figure 30, page 21. Place the brackets on the sections as given in
Figure 28. 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.
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 installed.
20
•
The side channels are labelled A and B in Figure 30.
Figure 29 gives the lengths of the side channel parts
for each model.
The channels at the boiler front and rear are part
numbers 426400030 & 426400031, respectively.
Figure 29 Upper and lower side channel lengths
Boiler
488
588
688
788
888
988
1088
1188
1288
1388
1488
1588
1688
1788
1888
Upper channel lengths
(inches)
Lower channel lengths
(inches)
A
B
A
B
30
38
46
54
62
35
43
43
51
51
51
59
67
67
71
NA
NA
NA
NA
NA
35
35
43
43
51
59
59
59
67
71
26
34
42
50
58
66
40
40
48
48
48
56
64
64
72
NA
NA
NA
NA
NA
NA
34
42
42
50
58
58
58
66
66
4. Attach the four jacket corners to the upper channels
as shown in callout , Figure 30, page 21. Corner part
numbers are: 426400054 (front left), 055 (front right),
056 (back left), and 057 (back right).
5. Attach the lower side, front and rear channels to the
jacket corners as shown in callouts
and
of Figure 30, page 21. Models 1088 and larger have two-piece
side channels. The channels are labelled A and B in
Figure 30. Figure 29 gives the lengths of these parts
for each model. Front and rear lower channels are part
numbers 426400032 and 426400033.
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Install jacket (continued)
Figure 30 Installing jacket support brackets, support channels and corners (piping and other components omitted for clarity)
Part No. 550-100-068/1018
21
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Install jacket (continued)
Install jacket front and back panels
Install jacket top panels
1. Slide the jacket front and back panels down over the top channels and
into the bottom channels as shown in Figure 32.
2. Slide the upper and lower channels as needed to square up the fit.
1. Place jacket top panels as shown in Figure 35, page 24.
• Remove knockouts for riser pipes and air bleed
piping (front section) using tin snips.
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 32.
• Butt the side panel against 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.
• 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.
• Tighten the screws securing the front and back panels to the rails.
3. Apply all jacket side panels in the order shown in Figure 34.
• 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 trim
2. Press jacket trim down over the front and side jacket
panels as shown in Figure 33.
Figure 32 Installing (removing) jacket front, rear
and side panels
Install top insulation
The 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. Cut insulation to length.
2. Center and align front and back of insulation to outside edges of front
and back sections.
3. Center insulation on top of sections, and fold sides of insulation until
folded sides of insulation compress between section and top mounting brackets.
Figure 31 Installing top insulation
22
Figure 33 Press jacket trim down over jacket front,
rear and side panels
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Install jacket (continued)
Figure 34 Jacket side panel placement
Part No. 550-100-068/1018
23
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Install jacket (continued)
Figure 35 Jacket top panel placement
24
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Pipe tankless heaters
Hot water can scald!
To pipe tankless heaters:
1. Size piping no smaller than heater inlet and outlet.
2. Automatic mixing valve must be installed. See Figure 37.
Follow manufacturer's instructions to install.
3. Flow regulating valve must be installed. Size according to continuous draw of heater. See Figure 36. Follow manufacturer's
instructions to install.
4. Operating control with small adjustable differential scale
is recommended. Install in temperature control tapping in
heater plate.
5. Multiple tankless heaters (see Figure 37):
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.
6. In hard water areas, soften cold domestic water supply to heaters to prevent lime build-up.
Tankless water heaters for the 88 boilers have
been tested and certified by
CSA Group (certificate # 2552127).
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.
NSF/ANSI 372
Figure 36 Tankless heater ratings (Weil-McLain ratings)
Heater
number
820
Intermittent
draw – GPM
(note 2)
Continuous
draw GPM
(notes 1, 2)
Inlet and
outlet tappings
8.5
8.0
¾"
Note 1
GPM based on 40–140°F DHW with boiler water
at 200°F
Note 2
Based on continuous draw with no recovery period
Children, elderly, infirm or physically handicapped persons are more likely to be injured
Figure 37 Tankless Heater Piping
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. 550-100-068/1018
25
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Install water boiler controls
Install controls:
Figure 38 Water control locations
1. Install furnished controls per Figure 39 and Figure 38.
Failure to properly install, pipe and wire boiler controls
can result in severe damage to boiler, building and personnel; 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.
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 cut-off
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 Figure 39 and Figure 38.
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. Dual limit 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 39 Water control tappings (see Figure 38)
Location
Size
A
2"
High limit
Manual reset limit
B
2"
Water relief valve
L
1"
Not used — plug
C1 & C2
1"
Alternate low water cut-offs
C1
Function
Combination high and low
limit control
D1 & D2
1"
Firing rate temperature
control (when used)
Low water cut-offs
E1 & E2
½"
—
F1 & F2
C\,"
—
G
¾"
Combination pressure–temperature gauge
H
¾"
Boiler drain
K
1"
Piping to compression tank or automatic air vent
M
2"
Drain
26
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Install steam boiler controls
Install controls:
Figure 41 Steam control locations
1. Install controls where shown in Figure 40 and Figure 41.
Failure to properly install, pipe and wire boiler controls
can result in severe damage to boiler, building and personnel; and is not covered by boiler warranty.
a. Install steam pressure operating and high limit controls and
pressure gauge. See Figure 40, Figure 41 and Figure 42, page 28.
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 fittings provided with boiler. Do not make any other connection in that piping.
Pipe relief valve discharge through vertical piping to atmosphere. Use rigid material suitable for 375°F, threaded
one end only. Install drain pan elbow to drain condensate.
Pipe near floor close to floor 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 40,
Figure 41 and Figure 44, page 28.
• Fittings for controls to be furnished by others.
• If water level control is not shown in Figure 43, page 28,
locate casting mark on control and install per manufacturer's instructions.
Do not use water level controls with quick hook-up fittings. Nuisance shutdowns will occur.
Figure 40 Steam control tappings (see Figure 41)
Location
Size
A
2"
Steam relief valve and/or
Skim tapping
B
2"
Steam relief valve
L
1"
Secondary probe low water cut-off
C1 & C2
1"
Low water cut-offs (see Figure 44, page 28)
C1
Function
—
D1 & D2
1"
Alternate low water cut-offs (see Figure 44, page 28)
E1 & E2
½"
Gauge glass
F1 & F2
C\,"
Try cock tappings
G
¾"
Pressure limit control,
Pressure operating control and pressure gauge,
Firing rate pressure control (when used)
H
¾"
Boiler drain (see Figure 18, page 15, for system blow-off
(drain) valve locations and sizes
K
1"
—
M
2"
Blowdown/drain
Part No. 550-100-068/1018
27
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Install steam boiler controls (continued)
Figure 42 Steam control siphon and fittings
Figure 43 Float-type water level control locations
Primary water level
control
Casting line
height above
bottom of gauge
glass
Back-up water level
control
Casting line
height above
bottom of gauge
glass
Note 1
"A"
Notes 1, 2
"B"
¼"
None
—
1½"
61, 63
½"
2C\,"
None
—
61, 63
150MD, 157MD
(see Note 3)
93, 193, 94
(see Note 3)
51-2 & 51-S-2
(see Note 3)
2"
150
¼"
2C\,"
61, 63
¼"
2C\,"
51-2 & 51-S-2
¼"
2"
None
—
2"
93, 193, 94
¼"
2"
61, 63
¼"
2"
51-2 & 51-S-2
¼"
1"to 1¼"
None
—
Notes:
1.
2.
3.
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 backup is needed. Do not install combination low water cutoff and feeder as back-up
control on boiler. Feeder will operate before pump control operates.
Figure 44 Water level control locations (see Figure 43)
28
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Connect breeching and venting systems
General venting information
1. Model 88 boilers operate with positive overfire pressure. Adjust
damper assembly (see Figure 51, page 33) during burner startup to achieve 0.1" W.C. positive pressure at damper sample hole.
Figure 45 Minimum breeching diameter
Boiler
model
Select type of venting system
Forced
draft
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 46 and Figure 48.
AHRI
vent or liner diameter
(inches)
Boiler flue collar
dimensions
(inches)
Balanced
draft
Note 1
488
10
12
10 round
588
10
15
10 round
688
12
15
10 round
788
12
18
12 round
888
14
18
12 round
Construct metal breeching:
988
14
18
14 round
1. See Figure 45 for minimum breeching diameter.
1088
14
21
14 round
2. Select material type and thickness in compliance with local
codes.
1188
16
21
14 round
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 is 3 feet. See Figure 47 and Figure 49.
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.
1288
16
21
14 round
1388
16
24
14 round
1488
18
24
16 round
3. Refer to ASHRAE Guide for chimney and breeching calculations
and construction and lining.
1588
18
24
16 round
1688
18
24
16 round
1788
18
24
16Z\, x 19M\, oval
1888
20
27
16Z\, x 19M\, oval
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 carbon monoxide emissions,
causing severe personal injury or death.
Note 1: Based on 15 feet chimney height, actual application
may vary, use AHRI/ASHRAE guidelines for each
individual installation.
Part No. 550-100-068/1018
29
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Connect breeching and venting systems
Figure 46 Stub vent – forced draft — single boiler
Figure 48 Stub vent – forced draft — multiple
Figure 47 Conventional chimney – balanced draft
Figure 49 Conventional chimney – balanced draft
with barometric draft control when
required — single boiler
30
boilers
with barometric draft control when
required — multiple boilers
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Install burner & wiring and fill system
To install burner
1. Unpack burner.
2. Place gasket around air tube and against burner mounting flange.
If sealing rope is used, apply 1/8" continuous bead of rope adhesive
around burner mounting flange and apply sealing rope to make
gas-tight seal.
3. Mount burner into opening in burner mounting plate.
For unusually hard water areas or low pH conditions
(less than 7.0) consult local water treatment company.
Provide a water softener for make-up water if hardness
exceeds 7 grains.
Freeze protection (when used)
(water boilers only)
Maintain gas-tight seal between burner mounting flange
and plate to prevent damage to air tube.
1. Use antifreeze especially made for hydronic systems.
Inhibited propylene glycol is recommended.
If a boiler base is Not utilized, the applicable burner
specification and boiler manual dimensions should be
reviewed for burner height to burner opening in the boiler. Some burner manufacturers may offer an optional
inversion kit to invert the burner allowing clearance to
the floor.
Do not use automotive, ethylene glycol
or undiluted antifreeze. Severe personal
injury or death can result.
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
Electric shock hazard. Can cause severe personal injury
or 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 - latest edition.
• Any additional national, state, or local codes.
2. Follow burner manual and wiring diagram found in burner information packet.
3. Use #14 AWG wire for operating and safety circuit wiring.
4. 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 - latest edition.
Determine if water treatment is needed
(water boilers only)
Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to system components can result, causing substantial property damage.
2. 50% solution provides protection to about -30°F.
3. Local codes may require back-flow preventer or
actual disconnect from city water supply.
4. Determine quantity 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. 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 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.
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. 550-100-068/1018
31
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Install fuel piping
Gas piping
Figure 50 Gas supply piping
1. In sizing the gas piping, the following factors should be considered:
a. Diameter and length of the gas supply piping.
b. Number of fittings.
c. 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 shutoff valve — see the burner manual and material list.
3. Follow good piping practices.
4. Pipe joint 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 50.
6. Piping must be supported by hangers, not by the burner or its
accessories.
7. 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
To prevent oil flow in case of oil line breakage:
7. Follow good piping practices.
•
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.
8. Pipe joint compound (pipe dope) must be resistant
to corrosive action of fuel oil. Apply sparingly only
to male threads of pipe joints.
Failure to comply could result in fuel leakage or fire, causing potential severe personal injury, death or substantial
property damage.
9. Supply and return piping should be sized to design
conditions, but not less than ½" O.D. continuous
copper tubing.
10. Auxiliary fuel oil pump is recommended when
suction line lift exceeds 12 feet.
1. A 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.
3. Use oil filter sized for fuel pump suction gear capacity.
4. Install oil filter.
11. Install swing joints so they will tighten as buried
tank settles to prevent fuel line breakage.
Do not install filter outside or close to an outside wall.
13. Install manual shut-off valve in suction line piping
near burner and where piping enters building from
outside tank.
5. Use continuous copper tubing to reduce possible piping leaks and
to ensure reliable seal when oil piping is buried.
6. Use flare fittings, not compression fittings.
Fire hazard — DO NOT USE soldered fittings. No safe
repair can be made.
32
12. 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.
14. Pitch suction line piping toward fuel tank.
15. Provide tee and plug at highest point in suction
line to release air from suction line and aid in
priming.
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Make final adjustments
Adjust burner and damper assembly:
Figure 51 Flue collar/damper assembly
1. Lock flue damper OPEN (Figure 51).
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.
3. Let burner advance to high fire. Heat boiler to design conditions.
4. Using combustion test equipment, adjust burner for:
a. 12% (± ¼%) CO2 for No. 2 fuel oil, 0 smoke.
b. 9 – 10% CO2 natural gas; CO in flue gas not to exceed 50 ppm
(0.01%).
c. Flue gas temperature no lower than 330°F.
On some applications, if draft conditions or burner characteristics cause the burner flame pattern to impinge on
the combustion chamber wall, you may notice pinging
sounds from the boiler. Adjust the burner if possible to
redirect the flame. If this does not work, contact your
boiler supplier or Weil-McLain to obtain an optional
combustion chamber kit (see page 38 for contents).
5. Adjust flue collar damper (Figure 51) to ensure 0.1" W.C. positive
pressure at test opening.
6. Tighten screws to secure in position.
7. Plug test opening with 1/8" plug provided with flue collar/damper
assembly.
8. Adjust barometric draft control, when used, to design conditions.
9. Repeat steps 4 through 6. Adjust as required.
Skim steam boilers:
Clean all newly installed steam boilers to remove oil.
Failure to properly clean can result in violent water level
fluctuations, 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.
Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to system components can result, causing substantial property damage.
Remove 2" plug from skim tapping "A" (see Figure 40, page 27).
Provide 2" skim piping from tapping to floor drain.
Raise waterline to midpoint of skim piping.
Fire burner to maintain temperature below steaming rate during
skimming process.
5. Feed in water to maintain water level.
6. Cycle burner ON/OFF as needed to prevent rise in steam pressure.
7. Continue skimming until discharge is clear. This may take several
hours.
1.
2.
3.
4.
Part No. 550-100-068/1018
8. Drain boiler.
9. While boiler is warm, but not hot, flush all interior 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
dissolved gases.
15. Stop burner.
16. Check traps and air vents for proper operation.
Check boiler for gas-tight seal:
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.
The 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.
2. Start burner. Observe all sealing points and chalk
mark any not gas-tight.
3. To seal all chalk-marked areas:
a. Use silicone sealant on section flueways.
b. Check gaskets and sealing rope placement.
4. Reinstall all jacket panels.
33
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Handling ceramic fiber and fiberglass materials
REMOVAL OF FRONT PLATE OR CLEANOUT PLATE MATERIALS
The burner front plate and clean out 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 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 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.
■ Eye: Irrigate immediately.
■ Breathing: Fresh air.
REMOVAL OR INSTALLATION OF FIBERGLASS WOOL:
This product contains fiberglass jacket insulation and ceramic fiber materials in jacket insulation, burner
front plate insulation and clean out 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 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 airborne fiber concentration requiring additional protection.
■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.
NIOSH stated First Aid.
■ Eye: Irrigate immediately.
■ Breathing: Fresh air.
34
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Ratings
AHRI Certified Ratings
Boiler
model
number
AHRI
burner
capacity
Light oil Gas
GPH MBH
Gross
AHRI
output
Net AHRI ratings
Steam Water Steam Steam
MBH MBH Sq. Ft MBH
Flue
Combustion Thermal Boiler Net
gas
efficiency efficiency H.P. firebox
volume volume
Water
MBH
Oil
Gas
Oil
Gas
Cubic
feet
CFM
Flue
Boiler Packaged
outlet water
boiler
dia. content weight
Inches Gallons Pounds
Notes:
1, 10
2, 3
2, 4
5, 6
5, 6
8
8
8
%
%
%
%
—
—
7
—
—
—
488R
6.9
996
827
833
2,583
620
719
87.5
84.8
85.6
83.1
24.7
11.02
376
10
109
2,860
488
7.0
1,010
839
844
2,621
629
730
87.5
84.8
85.6
83.1
25.1
11.02
370
10
109
2,860
588
9.4
1,356
1,126
1,135
3,521
845
979
87.0
84.4
85.6
83.1
33.6
14.45
507
10
132
3,340
688
11.8
1,701
1,413
1,424
4,469
1,072
1,229
86.7
84.1
85.6
83.1
42.2
18.08
639
10
155
3,820
788
14.2
2,046
1,700
1,713
5,463
1,311
1,478
86.5
83.9
85.6
83.1
50.8
21.61
772
12
178
4,345
788R
--
1999
1661
1673
5,463
1279
1,444
--
84.0
--
83.1
50.8
21.61
772
12
178
4,345
888
16.6
2,382
1,987
1,994
6,427
1,543
1,728
86.3
83.7
85.6
83.1
59.4
25.14
906
12
201
4,925
988R
17.2
2,482
2,062
2,080
6,671
1,601
1,793
86.2
83.7
85.6
83.1
61.6
28.67
1,031
14
224
5,600
988
18.8
2,737
2,274
2,294
7,358
1,766
1,977
86.2
83.7
85.6
83.1
67.9
28.67
954
14
224
5,600
1088R
20.0
2,887
2,399
2,419
7,763
1,863
2,086
86.2
83.6
85.6
83.1
71.7
32.20
1,184
14
247
6,130
1088
21.5
3,082
2,561
2,583
8,283
1,988
2,227
86.2
83.6
85.6
83.1
76.5
32.20
1,101
14
247
6,130
1188
23.5
3,428
2,848
2,873
9,213
2,211
2,477
86.1
83.5
85.7
83.1
85.1
35.76
1,299
14
270
6,695
1288
26.0
3,773
3,135
3,162
10,147
2,434
2,726
86.0
83.5
85.7
83.1
93.7
39.26
1,443
14
293
7,260
1388
28.5
4,119
3,422
3,456
11,071
2,657
2,976
86.0
84.4
85.7
83.1 102.2
42.79
1,588
14
316
7,890
1488
31.0
4,464
3,709
3,745
12,000
2,880
3,225
86.0
83.4
85.7
83.1
110.8
46.32
1,735
16
339
8,410
1588
33.0
4,809
3,996
4,035
12,925
3,102
3,475
85.9
83.3
85.7
83.1
119.4
49.85
1,854
16
362
9,005
1688R
34.5
4,979
4,137
4,182
13,383
3,212
3,597
85.9
83.3
85.7
83.1 123.6
53.38
2,003
16
385
9,525
1688
35.5
5,155
4,283
4,330
13,854
3,325
3,724
85.9
83.3
85.7
83.1 127.9
53.38
1,945
16
385
9,525
1788
38.0
5,494
4,570
4,615
14,783
3,548
3,974
85.9
83.3
85.7
83.1 136.5
56.91
2,152
18 *
408
9,780
1888
40.5
5,845
4,857
4,910
15,713
3,771
4,223
85.9
83.3
85.7
83.1 145.1
60.44
2,303
18 *
431
10,775
1.
See below to specify complete model number.
2.
Burner input based on maximum of 2,000 feet altitude. For other
altitudes, consult Weil-McLain distributor/agent or sales office.
3.
No. 2 fuel oil — Commercial Standard Spec CS75-56. Heating value of
oil = 140,000 Btu per gallon.
4.
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.
Part No. 550-100-068/1018
5.
Gross AHRI ratings have been determined under the AHRI
provision governing forced draft boiler-burner units.
6.
Flue gas volume at outlet temperature.
7.
Net AHRI ratings are based on net installed radiation of
sufficient quantity for the requirements of the building.
Nothing need be added for normal piping and pick-up.
Water ratings are based on a piping and pick-up allowance of
1.15.
Steam ratings are based on the following allowances: 488 – 588
= 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 or for unusual piping and pick-up loads.
Consult local Weil-McLain distributor/agent or sales office.
8.
With 0.10" W.C. positive pressure at flue collar.
9.
Water boilers tested for 80 PSIG, ASME water working
pressure. Steam boilers tested for 15 PSIG, ASME steam
working pressure.
*
Flue collar connection is oval, 16Z\," x 19M\,"
35
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Dimensions
Dimensions (inches)
Model
A
B
C
D
E
L
W
H
488
23
—
—
10
54 ¾
34 ¾
30
23 C\,
588
31
—
—
10
54 ¾
42 ¾
38
31 C\,
688
39
—
—
10
54 ¾
50 ¾
46
39 C\,
788
47
—
—
12
53 ¾
58 ¾
54
47 C\,
888
55
—
—
12
53 ¾
66 ¾
62
55 C\,
988
63
—
—
14
52 ¾
74 ¾
70
63 C\,
1088
71
—
—
14
52 ¾
82 ¾
78
71 C\,
1188
79
—
—
14
52 ¾
90 ¾
86
79 C\,
1288
87
39 ½
—
14
52 ¾
98 ¾
94
87 C\,
1388
95
47 ½
—
14
52 ¾
106 ¾
102
95 C\,
1488
103
55 ½
—
16
51 ¾
114 ¾
110
103 C\,
1588
111
63 ½
—
16
51 ¾
122 ¾
118
111 C\,
1688
119
47 ½
—
16
51 ¾
130 ¾
126
119 C\,
1788
127
31 ½
79 ½
51 ¾
138 ¾
134
127 C\,
1888
135
39 ½
87 ½
51 ¾
146 ¾
142
135 C\,
Model
Supply & return tappings
Supply tappings (No. & size)
488R
488
588
688
788
888
988R
988
1088R
1088
1188
1288
1388
1488
1588
1688R
1688
1788
1888
36
16Z\," x 19M\,"
oval
Burner lengths (Dimension F)
Return tappings (No. & size)
Steam
Water
Steam
Water
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
3 – 5"
3 – 5"
3 – 5"
3 – 5"
3 – 5"
3 – 5"
4 – 5"
4 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
2 – 5"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
1 – 6"
Carlin
Riello
PowerFlame
Beckett
Oil
Beckett
Gas
21
21
21
21
21
21
21
26
26
26
26
26
26
26
—
—
—
—
—
33
33
33
33
33
49
49
49
49
49
49
49
49
49
49
49
49
49
56
31
31
31
34
34
34
34
34
34
34
39
39
39
39
39
39
39
44
44
21
21
21
22
22
22
22
22
22
22
23
23
23
—
—
—
—
—
—
29
30
30
30
30
30
30
30
30
30
30
30
30
30
—
—
—
—
—
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Dimensions (continued)
Figure 52 Dimensions (see lettered dimensions on opposite page)
Part No. 550-100-068/1018
37
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
Parts
Item
Description
Part number
1
Front sections (8823)
316-301-210
2
Regular intermediate section (8825)
316-301-212
3
Tankless intermediate section (8826)
316-301-214
4
Back section (8828)
316-301-211
—
Supply intermediate section (8824) (not shown)
316-301-213
—
Section replacement kit (includes rope seals, rope adhesive and sealant for one joint)
5
Burner mounting plate
6
Sealing rope — ½" (7 feet per burner plate)
590-735-140
7
Tankless heater, when used, number 820
590-291-909
8
Heater gasket
590-317-579
9
Heater cover plate
450-030-934
10
Draw rod 5/8"-11UNC-2A x 13" (apply to front and rear sections)
560-134-505
11
Draft hood collar assembly
(includes damper collar, damper, damper quadrant, locking plate, swivel, brackets and rope)
a.
b.
c.
d.
e.
f.
g.
h.
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 . . . . . . . . . . . . . . . . . . . . . Quadrant for flue collar . . . . . . . . . . . . . . . . . . . . . . .
Damper blade . . . . . . . . . . . . . . . . . . . . . . . . . . . Damper locking plate . . . . . . . . . . . . . . . . . . . . . . . .
340-004-606
340-004-607
340-004-608
340-004-609
340-004-612
330-056-634
460-003-646
563-530-784
12
Sealing rope ½" ( 6 feet for flue collar)
590-735-140
13
Clean out plate
450-030-965
14
Woven fiberglass gasket for clean out plate
590-317-305
15
Observation port assembly (includes frame, rope, gasket, plugs and sight glass) (2 per boiler)
a. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Sight glass only . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Washer gasket for sight glass (2Z\, x 1Z\v x Z\, inches) . . . . . . . 385-600-099
591-419-199
590-317-580
16
Sealing rope, C\," (1 foot per observation port)
590-317-150
17
Burner mounting plate studs (½ x 3½ inches)
Obtain locally
18
Clean out plate nut, ¼"
Obtain locally
19
Cap screw, ½–13 x ¾"
Obtain locally
20
Observation port screw, 10–32 x 1½"
Obtain locally
21
Flue collar cap screw, ½" x 1½"
Obtain locally
22
Flue collar washer, ZZ\zn"
Obtain locally
23
Burner mounting plate washer, ½"
Obtain locally
24
Burner mounting plate nut, ½"
Obtain locally
25
Draw rod nut, B\,"
Obtain locally
26
Clean out plate washer, ¼"
Obtain locally
27
Clean out plate carriage bolt, ¼" x 1¾"
Obtain locally
28
HXT-bars (see Figure 13, page 13, for installation and placement details for HXT-bars)
Not shown
38
386-300-213
Order for specific burner
d. 3-flueway kit (includes 3 sets of bars)
e. 2-flueway kit (includes 2 sets of bars)
Combustion chamber liner kit (optional) — includes ceramic fiber blanket for left side wall plus water glass adhesive — see
page 33. Consult your local Weil-McLain sales office for details.
416-400-130
416-400-131
Contact local Weil-McLain
sales office
Part No. 550-100-068/1018
Boiler manual:
• Installation
• Start-Up
• Maintenance
• Parts
Parts (continued)
Figure 53 Parts
Part No. 550-100-068/1018
39
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
40
Part No. 550-100-068/1018