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.
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.
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 . . . . . . . . . . . . . . . . . . .
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, when applicable. 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 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 inju
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.
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. Figure 5 Boiler model number The boiler contains ceramic fiber and fiberglass materials.
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 Figure 7 Silicone sealant 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.
Boiler manual: • Installation • Start-Up • Maintenance • Parts Assembling the block 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.
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 Max.
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 overpressure. 3.
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 1. Install four ½" x 3½" 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: a.
Boiler manual: • Installation • Start-Up • Maintenance • Parts Complete block assembly (continued) DO NOT insert a bottom HXT-bar into the opening between the FRONT section and the first intermediate section. Figure 13 Cleanout plate assembly 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 12, page 12.
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.
Boiler manual: • Installation • Start-Up • Maintenance • Parts Connect water boiler piping (continued) Figure 16 Recommended minimum pipe sizes when flow rate is not known (see Figure 14, page 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 18 By-pass piping for return water less than Pipe sizes are based on a 20°F temperature rise through the boiler.
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.
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.
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) 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 4 Equ
Boiler manual: • Installation • Start-Up • Maintenance • Parts Connect steam boiler piping (continued) 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- ing 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 42, page 28.
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. 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.
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.
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 1. Slide the jacket front and back panels down over the top channels and into the bottom channels as shown in Figure 30. 2. Slide the upper and lower channels as needed to square up the fit. Figure 30 Installing (removing) jacket front, rear and side panels Install jacket side panels 1. Remove jacket side panels from cartons. 2.
Boiler manual: • Installation • Start-Up • Maintenance • Parts Install jacket (continued) Figure 32 Jacket side panel placement Part No.
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 24 Part No.
Boiler manual: • Installation • Start-Up • Maintenance • Parts Pipe tankless heaters To pipe tankless heaters: Hot water can scald! Consumer Product Safety Commission and some states recommend domestic hot water temperature of 130°F or less. 1. See Figure 35. 2. Size piping no smaller than heater inlet and outlet. 3. Automatic mixing valve must be installed. See Figure 35. Follow manufacturer's instructions to install. 4. Flow regulating valve must be installed.
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 1. 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 personnel; and is not covered by boiler warranty. 2. Relief valve must be installed with spindle in vertical position. Use fittings provided with boiler.
Boiler manual: • Installation • Start-Up • Maintenance • Parts Install steam boiler controls Install controls: Figure 39 Steam control locations 1. 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 personnel; and is not covered by boiler warranty. a. Install steam pressure operating and high limit controls and pressure gauge. See Figure 38, Figure 39 and Figure 40, 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 Steam control siphon and fittings Figure 41 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,
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 49, page 33) during burner start-up to achieve 0.1" W.C. positive pressure at damper sample hole.
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 Stub vent – forced draft — single boiler Figure 46 Stub vent – forced draft — multiple boilers Figure 45 Conventional chimney – balanced draft with barometric draft control when required — single boiler 30 Figure 47 Conventional chimney – balanced draft with barometric draft control when required — multiple boilers Part No.
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. Maintain gas-tight seal between burner mounting flange and plate to prevent damage to air tube. 4.
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 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.
Boiler manual: • Installation • Start-Up • Maintenance • Parts Make final adjustments Adjust burner and damper assembly: Figure 49 Flue collar/damper assembly 1. Lock flue damper OPEN (Figure 49). 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.
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.
Boiler manual: • Installation • Start-Up • Maintenance • Parts Ratings Boiler model number I=B=R burner capacity Light oil Gas GPH MBH Gross I=B=R output MBH Net I=B=R ratings Steam Steam Sq. Ft MBH Boiler H.P. Combustion efficiency Thermal efficiency Net firebox volume Flue gas volume Oil Gas Oil Gas Cubic feet CFM Inches W.C.
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\, 1
Boiler manual: • Installation • Start-Up • Maintenance • Parts Dimensions (continued) Figure 50 Dimensions (see lettered dimensions on opposite page) Part No.
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) 386-300-213 5 Burner mounting p
Boiler manual: • Installation • Start-Up • Maintenance • Parts Parts (continued) Figure 51 Parts Part No.
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners Warranty Weil-McLain Limited Warranties Residential & Commercial Cast Iron Boilers Indirect-Fired Water Heaters Residential Water Warranty — Limited Lifetime Residential Steam Warranty — Limited 10 Year Commercial Warranty — Limited 10 Year First Year — (All Residential & Commercial Cast Iron Boilers) Weil-McLain warrants that its cast iron boilers are free from defects in material and workmanship for
