Table of Contents
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Boiler Manual
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.
88
Water & steam boilers – Series 2
for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners
• Installation
• Startup
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.
• Maintenance
• Parts
For additional
information, refer to . .
Burner
specification and
data sheets
for burners pre-tested
with model 88 boilers
Part No. 550-100-068/1009
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Table of Contents
Related Manuals for Weil-McLain 88
Summary of Contents for Weil-McLain 88
- Page 1 . . Burner specification and data sheets for burners pre-tested with model 88 boilers INSTALLER This manual must only be used by a qualified Consider piping and installation when determining heating installer/service technician. Read all boiler location.
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Page 2: Hazard Definitions
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 concern- ing the life of the product. -
Page 3: Table Of Contents
Boiler manual: • Installation • Start-Up • Maintenance • Parts Contents Before installing boiler Set boiler in place Assembling the block Perform hydrostatic pressure test Complete block assembly Connect water boiler piping Connect steam boiler piping Install jacket Pipe tankless heaters Install water boiler controls Install steam boiler controls Connect breeching and venting systems... -
Page 4: Before Installing Boiler
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 State, provincial and local plumbing, heating and electrical codes. - Page 5 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 Adequate combustion and ventilation air must be provided to assure proper combustion and prevent possibility of flue gas leakage and carbon monox- ide emissions, causing severe personal injury or death.
- Page 6 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: system, the combustion air shall be supplied from outdoors at the minimum rate of 0.35 ft /minute per •...
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Page 7: Set Boiler In Place
Ensure the equipment and cables used for lifting are de- Figure 5 Section assembly lifting weights signed 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 Boiler Approximate Minimum property damage. -
Page 8: Assembling The Block
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Assembling the block Figure 6 Sealing rope installation Sections are top heavy. Unbolted sections may fall if not supported, resulting in severe personal injury or death. - Page 9 Install tankless heaters and gaskets or heater cover openings or sockets, or misaligned lugs. If corrections are made plates and gaskets. Use " x " studs, washers and gap still exists, contact your Weil-McLain distributor or sales office before continuing installation. and nuts. Part No. 550-100-068/1009...
- Page 10 Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Assembling the block (continued) Figure 9 Section arrangement Boiler model Section arrangement number number (all heaters must be on left side of boiler)
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Page 11: Perform Hydrostatic Pressure Test
Boiler manual: • Installation • Start-Up • Maintenance • Parts Perform hydrostatic pressure test Prepare boiler and test: Figure 11 Boiler tappings Figure 10 and Figure 11 for tapping locations. Install: Boiler drain (not furnished). Water pressure gauge — for test only. Be sure gauge can handle test pressure —... -
Page 12: Complete Block Assembly
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 Position " sealing rope in groove. Secure assembly to section. Use 10-32 x ¾"... - Page 13 Boiler manual: • Installation • Start-Up • Maintenance • Parts Complete block assembly (continued) DO NOT insert a bottom HXT-bar into the opening Figure 13 Cleanout plate assembly between the FRONT section and the first intermediate section. 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.
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Page 14: Connect Water Boiler Piping
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 14 Water boiler piping, typical System water supply and return piping should be installed and piping connections attached to boiler before erecting jacket or installing controls. - Page 15 Calculate only secondary (boiler) piping circuit resistance. Al- 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 control panel. Size secondary (boiler) circuit piping using the flow rate ranges given in Figure 17, page 15.
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Page 16: Connect Steam Boiler Piping
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 20 Cold water fill piping Hartford loop piping arrangement and wet return are required for steam boilers. - Page 17 Pipe sizes shown are for two-pipe, pumped-return systems. Adjust pipe sizing as needed when connecting to gravity-return systems. Consult local Weil-McLain distributor or sales office before installing alternate piping. Steam boiler piping guidelines Minimum height of header above water line must...
- Page 18 Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Connect steam boiler piping (continued) Figure 25 Model 1288 through 1888 steam (3 or 4 risers required) Drawing legend & notes (Figure 23 through Figure 26)
- Page 19 Use a Weil-McLain Boiler Control Sys- level indicated in Figure 42, page 28. Provide at tem (such as a BCP panel) to open each steam point A either: valve automatically before firing burner.
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Page 20: Install Jacket
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Install jacket Before installing jacket Figure 27 Place support brackets as listed below The boiler contains ceramic fiber and fiberglass materials. Boiler... - Page 21 Boiler manual: • Installation • Start-Up • Maintenance • Parts Install jacket (continued) Figure 29 Installing jacket support brackets, support channels and corners (piping and other components omitted for clarity) Part No. 550-100-068/1009...
- Page 22 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 Figure 30 Installing (removing) jacket front, rear and side panels Slide the jacket front and back panels down over the top channels and into the bottom channels as shown in Figure 30.
- Page 23 Boiler manual: • Installation • Start-Up • Maintenance • Parts Install jacket (continued) Figure 32 Jacket side panel placement Part No. 550-100-068/1009...
- Page 24 Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Install jacket (continued) Figure 33 Jacket top panel placement Part No. 550-100-068/1009...
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Page 25: Pipe Tankless Heaters
In hard water areas, soften cold domestic water supply to heaters to prevent lime build-up. Consumer Product Safety Commission and some Figure 34 Tankless heater ratings (Weil-McLain states recommend domestic hot water tempera- ratings) ture of 130°F or less. When installing an automatic mixing valve, se-... -
Page 26: Install Water Boiler Controls
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 37 Water control locations Install furnished controls per Figure 36 and Figure 37. Failure to properly install, pipe and wire boiler controls can result in severe damage to boiler, building and per- sonnel;... -
Page 27: Install Steam Boiler Controls
Boiler manual: • Installation • Start-Up • Maintenance • Parts Install steam boiler controls Install controls: Figure 39 Steam control locations Install controls where shown in Figure 38 and Figure 39. Failure to properly install, pipe and wire boiler controls can result in severe damage to boiler, building and per- sonnel;... - Page 28 Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Install steam boiler controls (continued) Figure 40 Figure 41 Steam control siphon and fittings Float-type water level control locations Primary water level...
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Page 29: Connect Breeching And Venting Systems
• Parts Connect breeching and venting systems General venting information Figure 43 Minimum breeching diameter Model 88 boilers operate with positive overfire pressure. Adjust damper assembly (see Figure 49, page 33) during burner start-up Boiler I=B=R Boiler flue to achieve 0.1" W.C. positive pressure at damper sample hole. - Page 30 Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Connect breeching and venting systems Figure 44 Figure 46 Stub vent – forced draft — single boiler Stub vent – forced draft — multiple...
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Page 31: Install Burner & Wiring And Fill System
Boiler manual: • Installation • Start-Up • Maintenance • Parts Install burner & wiring and fill system To install burner For unusually hard water areas or low pH conditions (less than 7.0) consult local water treatment company. Unpack burner. Provide a water softener for make-up water if hardness exceeds 7 grains. -
Page 32: Install Fuel Piping
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Install fuel piping Gas piping Figure 48 Gas supply piping In sizing the gas piping, the following factors should be consid- ered: Diameter and length of the gas supply piping. -
Page 33: Make Final Adjustments
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). Drain boiler. -
Page 34: Handling Ceramic Fiber And Fiberglass Materials
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 cleanout plate gaskets contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications. -
Page 35: Ratings
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. Burner input based on maximum of 2,000 feet altitude. For other altitudes, consult Weil-McLain distributor/agent or sales office. -
Page 36: Dimensions
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Dimensions Dimensions (inches) Model — — 54 ¾ 34 ¾ 23 C\, — — 54 ¾ 42 ¾ 31 C\, — —... - Page 37 Boiler manual: • Installation • Start-Up • Maintenance • Parts Dimensions (continued) Figure 50 Dimensions (see lettered dimensions on opposite page) Part No. 550-100-068/1009...
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Page 38: Parts
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Parts Item Description Part number Front sections (8823) 316-301-210 Regular intermediate section (8825) 316-301-212 Tankless intermediate section (8826) 316-301-214 Back section (8828) 316-301-211 —... - Page 39 Boiler manual: • Installation • Start-Up • Maintenance • Parts Parts (continued) Figure 51 Parts Part No. 550-100-068/1009...
- Page 40 Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Part No. 550-100-068/1009...