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88
Water & steam boilers – Series 2
for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners
• Maintenance
• Installation
Boiler Manual
• Parts
• Startup
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 INSTALLER Consider piping and installation when determining
heating installer/service technician. Read all boiler location.
instructions before installing. Follow all
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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. Indicates presence of hazards that will cause severe personal injury, death or substantial property damage if ignored. Indicates presence of hazards that ca
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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 ste
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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 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, when applicable. 5. National codes where applicable. Before selecting boiler loca
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Boiler manual: • Installation • Start-Up • Maintenance • Parts (continued) Before installing boiler 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 monoxide emissions, causing severe personal injury or death. Do not install an exhaust fan in boiler room. Incor- rect burne
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Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners (continued) Before installing boiler freely communicate with the outdoors, as follows: system, the combustion air shall be supplied from 3 outdoors at the minimum rate of 0.35 ft /minute per • Where directly communicating with the outdoors or where 3 1000 Btuh (0.034 m /min per kW) for all appliances communicating to the outdoors through vertical ducts, each 2 located within the space. o
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Boiler manual: • Installation • Start-Up • Maintenance • Parts Set boiler in place Ensure the equipment and cables used for lifting are Figure 5 Section assembly lifting weights 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 Boiler Approximate Minimum model lifting sling length — property damage. number weight (from crane hook to (pounds) boiler lifti
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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. Prepare and position back section 1 1. Apply / " continuous bead of sealing rope adhesive in sealing rope 8 grooves. See Figure 6. Do not get any adhesive on machined port surfaces. 2. Place ½" sealing rope in groove. Arou
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Boiler manual: • Installation • Start-Up • Maintenance • Parts Assembling the block Figure 8 Sealing ring installation and port Sections are top heavy. Unbolted sections may fall alignment if not supported, resulting in severe personal injury or death. Install intermediate sections 3 1. Remove and discard / " diameter shipping tie rods. 8 2. Remove grit from port machined surfaces with clean rag. Do not use petroleum-based cleaning or sealing com- pounds in boiler system. Sever
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Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners (continued) Assembling the block Figure 9 Section arrangement Max Boiler model Section arrangement number (all heaters must be on left side of boiler) number of W = water F = front / B = back / I = Intermediate tankless S = steam heaters TI = tankless intermediate SI = supply intermediate (steam only) "I" can be substituted for "TI" sections 488 W&S 1 F • TI • I • B 588 W&S 2 F
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Boiler manual: • Installation • Start-Up • Maintenance • Parts Perform hydrostatic pressure test Prepare boiler and test: Figure 11 Boiler tappings 1. See Figure 10 and Figure 11 for tapping locations. Install: a. Boiler drain (not furnished). 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. Do not pressure test with any control installed. Damage to control can occur due to
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Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Complete block assembly 3 b. Position / " sealing rope in groove. Install burner mounting plate on front 8 c. Secure assembly to section. Use 10-32 x ¾" section truss-head screws. 1. Install four ½" x 3½" studs to secure burner mounting plate to 2. Repeat above steps for back observation port as- section: sembly. a. Thread and lock together two nuts on rounded end of stud. Thread flat end of
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Boiler manual: • Installation • Start-Up • Maintenance • Parts (continued) Complete block assembly DO NOT insert a bottom HXT-bar into the opening Figure 13 Cleanout plate assembly 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 Fig- ure 12, page 12. Install cleanout plates Cleanout plates
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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 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
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Boiler manual: • Installation • Start-Up • Maintenance • Parts (continued) Connect water boiler piping Figure 16 Recommended minimum pipe sizes when flow rate is Figure 18 By-pass piping for return water less than not known (see Figure 14, page page 14) (note 1) 140°F Boiler Supply pipe size Return pipe size model A B 488 3" 3" 588 – 788 4" 4" 888 – 1188 5" 5" 1288 – 1888 6" (note 2) 6" (note 2) By-pass circulator sizing: Note 1 Pipe sizes are based on a 20°F temperature rise thr
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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 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 b
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Boiler manual: • Installation • Start-Up • Maintenance • Parts (continued) Connect steam boiler piping Improperly piped systems or undersized piping can Figure 23 Model 488 through 688 steam (1 riser) contribute to erratic boiler operation and possible boiler or system damage. Piping system must be installed as shown, using pipe sizes shown. Pipe sizes shown are for two-pipe, pumped-return systems. Adjust pipe sizing as needed when connecting to gravity-return systems. Cons
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Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners (continued) Connect steam boiler piping Figure 25 Model 1288 through 1888 steam (3 or 4 risers required) Drawing legend & notes (Figure 23 through Figure 26) 1 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
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Boiler manual: • Installation • Start-Up • Maintenance • Parts (continued) Connect steam boiler piping Figure 26 Multiple Steam Boiler Piping Gravity Condensate Return See page 18 for numbered circle references. A Pipe as shown for gravity return systems, connect- D Install stop valves per ASME code requirements. ing point A to the wet gravity return. • F or pump-return systems, if using automatic • For pumped-return systems, install boiler water steam valves, use only slow-o
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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 Upper brackets on Lower brackets Use care when handling these materials per instructions sections: on sections: on page 34 of this manual. Failure to comply could result 488 2, 3 None 588 2, 4 None in severe personal injury. 688 2, 5 None
