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Water & steam boilers
for use with Gas, Light Oil, &
Gas/Light Oil – Fired Burners
80
Boiler Manual
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.
• Consider piping and installation when determining boiler location.
INSTALLER
Any claims for damage or shortage in shipment must be file
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners Contents Page 1. Before installing boiler .................................................................................. 3 2. Set boiler in place........................................................................................... 5 3. Assemble block .............................................................................................. 6 4. Perform hydrostatic pressure test ...................................
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• Installation Start-Up Maintenance Parts Before installing boiler 1 Installation must comply with — Lay a foundation, if needed: Floor construction and condition must be suitable for State, provincial and local plumbing, heating and electrical codes. weight of boiler when filled with water. See page 34 for approximate boiler operating weight. Regulations of servicing utilities. A level concrete or brick foundation (constructed per National codes where applicable. Table 1 an
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 1 Before installing boiler (continued) Provide combustion and ventilation air Figure 2 Combustion and ventilation air openings: openings — Boiler room below grade Do not install an exhaust fan in boiler room. 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. Opening sizes must c
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Installation Start-Up Maintenance Parts 2 Set boiler in place For packaged boiler: Cables are not intended for long-term usage. Cables may corrode inside boiler, 1. Remove top jacket panels. Set aside until after boiler is weakening their lifting strength. Failure to piped. remove cables can result in severe personal injury, death or substantial property The boiler contains ceramic fiber and damage. fiberglass materials. Use care when handling these materials per instructions 6.
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 3 Assemble block Sections are top heavy. Unbolted sections Do not use petroleum-based cleaning or may fall if not supported, resulting in sealing compounds in boiler system. severe personal injury or death. Severe damage to system components can result, causing substantial property damage. Install back refractory blanket 4. Place 7½" and 3½" sealing rings in appropriate port 1. Lay back section on floor with ports face up. ope
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Installation Start-Up Maintenance Parts 3 Assemble block (continued) Install intermediate sections Figure 6 Sealing ring installation and port alignment Sections are top heavy. Unbolted sections may fall if not supported, resulting in severe personal injury or death. 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 compounds in boiler system. Severe damage to sys
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 4 Perform hydrostatic pressure test Prepare boiler and test: 1. See pages 28 and 29 for tapping locations. Install: a. Boiler drain (not furnished). b. Water pressure gauge — for test only. Be sure gauge can handle test pressure — see step 3. c. Air vent in upper tapping (K). 2. Plug remaining tappings. Do not pressure test with any control installed. Damage to control can occur due to overpressure. 3. Fill boiler. Vent all ai
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Installation Start-Up Maintenance Parts 5 Complete block assembly Install burner mounting plate on front section 1. Install four ½" x 4¾" studs to secure burner mounting plate to section: a. Thread and lock together two nuts on rounded end of stud. Thread flat end of stud into one of four holes located around opening. b. Remove nuts. c. Repeat steps a and b for remaining studs. 2. Install burner mounting plate: 1 a. Apply / " continuous bead of sealing rope adhesive in groove ar
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 6 Install flue collector Flue collector assembly 2. Wipe all flanged surfaces with clean rag. 1. Figure 10, page 11, shows flue collector components 3. Lay flue collector hood gasket (item 2) on flange. and locations. Figure 11, page 13, shows collector hoods 4. Place flue collector end cap (item 1) on gasket. Align for all models. Follow all instructions in this manual to 5 5 bolt holes. Secure with seven / " x / " flanged bo
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Installation Start-Up Maintenance Parts 6 Install flue collector (continued) Figure 10 Flue collector components, typical (Model 880 collector configurations shown) Part No. 550-141-935/0602 11
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 6 Install flue collector (continued) DO NOT overtighten bolts in flue collector hood assembly. Before installing flue collector Gasket material could extrude, causing possible flue gas leakage 1. See Figure 10, page 11, for general assembly of flue and carbon monoxide emissions, resulting in severe personal collector components. injury or death. 2. See Figure 11, page 13 for the placement of flue collector hoods on each model.
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Installation Start-Up Maintenance Parts 6 Install flue collector (continued) Figure 11 Flue collector components by model (see Figure 10, page 11 for flue collector components not shown below) Part No. 550-141-935/0602 13
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 7 Connect water boiler piping General water piping information: Table 6 Recommended minimum pipe sizes for System water supply and return piping should be installed and piping known flow rates. connections attached to boiler before erecting jacket or installing controls. Do not pipe in through supply and out through return. This creates reverse water flow through boiler that must not be used. When three-way valves are us
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Installation Start-Up Maintenance Parts 7 Connect water boiler piping (continued) 3. Piping for multiple boilers (see Figure 13): Figure 13 Multiple water boiler piping A Size secondary boiler pump GPM based on following formulas: Gross output = GPM Temperature rise x 500 Temperature rise, °F = 230°F – Return water temperature Gross output is in Btuh. Calculate only secondary piping circuit resistance. Boiler resistance will be about equal to three 90 degree elbows of secon
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 8 Connect steam boiler piping General steam piping information: c. Connect cold water fill piping as shown in Figure 14. Also shown are recommended valves and water Hartford loop piping arrangement and wet return are meter, if used. Water meter will detect added required for steam boilers. Use the Hartford loop for makeup water, indicating leaks in system. both pumped-return and gravity-return systems. 2. Condensate piping:
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Installation Start-Up Maintenance Parts 8 Connect steam boiler piping (continued) Figure 15 Model 380 through 580 steam boiler piping — NOTE minimum 24 inches between boiler water line and bottom of header. Figure 16 Model 680 through 980 steam boiler piping — NOTE minimum 24 inches between boiler water line and bottom of header. Part No. 550-141-935/0602 17
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 8 Connect steam boiler piping (continued) Figure 17 Model 1080 through 1280 steam boiler piping — NOTE minimum 24 inches between boiler water line and bottom of header. Figure 18 Condensate piping to boiler Table 9 Condensate receiver capacity 18 Part No. 550-141-935/0602
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Installation Start-Up Maintenance Parts 8 Connect steam boiler piping (continued) Figure 19 Multiple Steam Boiler Piping Gravity Condensate Return A Pipe as shown for gravity return systems, connecting D Install stop valves per ASME code requirements. point A to the wet gravity return. For pump-return systems, if using automatic steam For pumped-return systems, install boiler water level valves, use only slow-opening automatic valves. Use a control on each boiler with body ma
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Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 9 Install jacket The boiler contains ceramic fiber and Before installing jacket fiberglass materials. Use care when handling these materials per instructions 1. Packaged boilers on page 38 of this manual. Failure to Install top jacket panels per instructions in this comply could result in severe personal manual. injury. 2. Non-packaged boilers Follow the instructions in this section to install all jacket panels. Remove jac
