Weil-McLain 380 User manual
Part number 550-141-935/1009
Part No. 550-141-935/0215
s)NSTALLATION
s3TARTUP
s-AINTENANCE
s0ARTS
–80 –
Water & Steam Boilers
For Gas, Light Oil, & Gas/Light Oil-Fired Burners
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.
s #ONSIDERPIPINGANDINSTALLATIONWHENDETERMININGBOILERLOCATION
s !NYCLAIMSFORDAMAGEORSHORTAGEINSHIPMENTMUSTBElLEDIMMEDIATELYAGAINSTTHETRANSPORTATIONCOMPANY
by the consignee.
s 4HISMANUALISFORUSEONLYBYYOURQUALIlEDHEATINGINSTALLERSERVICETECHNICIAN
s "OILERANDBURNERMUSTBEINSTALLEDBYAQUALIlEDSERVICETECHNICIAN
s 7ERECOMMENDREGULARSERVICEBYAQUALIlEDSERVICETECHNICIANATLEASTANNUALLY
7HENCALLINGORWRITINGABOUTTHEBOILER0LEASEHAVETHEBOILERMODELNUMBERFROMTHEBOILERRATINGLABELAND
THE#0NUMBERFROMTHEBOILERJACKET
INSTALLER
USER
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
2 Part No. 550-141-935/0215
(AZARD$ElNITIONS
The following defined terms are used throughout this manual to bring attention to the presence of hazards of
VARIOUSRISKLEVELSORTOIMPORTANTINFORMATIONCONCERNINGTHELIFEOFTHEPRODUCT
Indicates presence of hazards that WILLCAUSESEVERE personal injury, death or substantial property
damage if ignored.
Indicates presence of hazards that CANCAUSESEVERE 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 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.
Contents
1. Before installing boiler ..................................................................3
2. Set boiler in place ..........................................................................5
3. Assemble block..............................................................................6
4. Perform hydrostatic pressure test .................................................8
5. Complete block assembly ..............................................................9
.....................................................................10
7. Connect water boiler piping ........................................................14
8. Connect steam boiler piping........................................................16
9. Install jacket ................................................................................20
10. Pipe tankless heaters...................................................................27
11. Install water boiler controls.........................................................28
12. Install steam boiler controls ........................................................29
13. Connect breeching and venting system.......................................31
14. Install burner ...............................................................................32
15. Wiring and fuel piping..................................................................32
................................................................32
17. Dimensions and ratings ...............................................................34
18. Parts ............................................................................................36
..........................38
Page
s)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
3Part No. 550-141-935/0215
)NSTALLATIONMUSTCOMPLYWITH
s 3TATEPROVINCIAL ANDLOCALPLUMBINGHEATING AND
electrical codes.
s 2EGULATIONSOFSERVICINGUTILITIES
s .ATIONALCODESWHEREAPPLICABLE
"EFORESELECTINGBOILERLOCATION
#HECKFORNEARBYCONNECTIONSTO
a. Fuel supply
b. Electrical power
c. System water or steam piping
d. Venting systems - see page 31
E #OMBUSTIONANDVENTILATIONAIRSUPPLY SEE
“Provide combustion and ventilation air supply
openings” on page 4.
#HECKAREA AROUND BOILER2EMOVEANY COMBUSTIBLE
materials, gasoline and other flammable vapors and
liquids.
&AILURETOKEEPBOILERAREACLEARANDFREE
of combustible materials, gasoline and
other flammable liquids and vapors can
result in severe personal injury, death and
substantial property damage.
1Before installing boiler
0ROVIDECLEARANCEAROUNDBOILER
s 0ROVIDE MINIMUM CLEARANCES TO COMBUSTIBLE
MATERIALS
1. Single-wall vent pipe – 18 inches.
2. Double-wall vent pipe – refer to vent pipe
manufacturer’s recommendations for vent pipe
clearances.
"OILERTOPINCHES
"OILERFRONTINCHES
"OILERmUEINCHES
"OILERREARINCHES
"OILERSIDESINCHES
s "OILERMAYBEINSTALLEDONCOMBUSTIBLEmOORING
s 3EEPAGESANDFORBOILERDIMENSIONS
&LUEPIPEBREECHINGCLEARANCESTAKE
PRECEDENCEOVERJACKETCLEARANCES
s ,EFTSIDEFORCLEANINGANDTANKLESSHEATERREMOVALn
34 inches.
s !LLOWSUFlCIENTSPACEONREMAININGSIDESFORCLEANING
servicing and burner installation. See burner literature
for length and recommended service clearances.
&IGURE Boiler foundation
4ABLE Boiler foundation (see Figure 1)
,AYAFOUNDATIONIFNEEDED
Floor construction and condition must be suitable for
weight of boiler when filled with water. See page 34 for
approximate boiler operating weight.
!LEVELCONCRETEORBRICKFOUNDATIONCONSTRUCTEDPER
4ABLEAND&IGUREISREQUIREDWHEN
!mOORCOULDPOSSIBLYBECOMEmOODED
2. Non-level conditions exist.
"OILER
MODEL
NUMBER
“Lv
,ENGTH
(inches)
"OILER
MODEL
NUMBER
“Lv
,ENGTH
(inches)
380 23 880 58
480 30 980 65
580 37 72
680 44 79
780 51 86
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
4 Part No. 550-141-935/0215
Before installing boiler (continued)
1
&IGURE Combustion and ventilation air openings
— Boiler room below grade
&IGURE Combustion and ventilation air openings
— Boiler room partially or completely
above grade
0ROVIDECOMBUSTIONANDVENTILATIONAIR
OPENINGS
Do not install an exhaust fan in boiler
ROOM !DEQUATE COMBUSTION AND
ventilation air must be provided to
assure proper combustion and prevent
POSSIBILITYOFmUEGASLEAKAGEANDCARBON
monoxide emissions, causing severe
personal injury or death.
Opening sizes must comply with state, provincial or
local codes. In their absence, use the following when
BOILERISINACONlNEDROOM
s 0ROVIDETWOPERMANENT OPENINGS IN BOILERROOM
one within 12 inches of ceiling, one within 12 inches
of floor. Minimum dimension of each opening is 3
inches.
7HENALL AIR IS TAKENFROMWITHINBUILDINGEACH
opening should be at least one square inch/1,000
"TUHBOILER INPUT ANDFREELYCONNECTWITH AREAS
having adequate infiltration from outside.
7HENALLAIRISTAKENFROMOUTDOORSEACHOPENING
should connect directly or by ducts from outdoors
or crawl or attic spaces that freely connect with
OUTDOORSANDSIZEDASLISTEDBELOW
a. through outside wall or vertical ducts - at least
ONESQUAREINCH"TUHBOILERINPUT
b. through horizontal ducts - at least one square
INCH"TUHBOILERINPUT
c. where ducts are used, they should be same cross-
sectional area as free area of openings they are
connected to.
D COMPENSATEFORLOUVERGRILLEORSCREENBLOCKAGE
when calculating free air openings. Refer to
their manufacturer’s instructions for size. If
UNKNOWNUSE
s WOODLOUVERSFREEAIR
s METALLOUVERSORGRILLESFREEAIR
s SCREENSNOTLESSTHANINCHMESH
,OCKLOUVERSINOPENPOSITIONORINTERLOCKWITHEQUIP-
ment to prove open before boiler operation.
7HENCOMBUSTIONANDVENTILATIONAIRENTERSTHROUGH
sidewall openings, ensure openings comply with Fig-
ures 2 and 3.
s)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
5Part No. 550-141-935/0215
3ETBOILERINPLACE
2
&ORPACKAGEDBOILER
2EMOVETOPJACKETPANELS3ETASIDEUNTILAFTERBOILERIS
piped.
The boiler contains ceramic fiber and
fiberglass materials. Use care when
handling these materials per instructions
on page 38 of this manual. Failure to
comply could result in severe personal
injury.
2EMOVELAGSCREWSINFRONTINREARFROMSHIPPING
rails.
2EMOVEBOILERFROMSKID#ABLESAREALREADYATTACHED
TOBLOCKASSEMBLY3EE4ABLEFORLIFTINGWEIGHT
s 5SINGCRANEHOOKMIDDLEOFEACHCABLETOEYEOF
crane.
s 5SINGHOISTHOOKMIDDLEOFEACHCABLETOHOIST
2AISEBOILER OFF SKID5SEPIPEROLLERSUNDER SKID
angles to roll boiler.
0LACEBOILER INFINALPOSITION#ENTERBOILERON
foundation, if used.
,EVELBOILER3HIMUNDERSKIDANGLESIFNECESSARY
#UTOFFCABLES
#ABLESARENOT INTENDED FOR LONGTERM
USAGE#ABLESMAYCORRODEINSIDEBOILER
WEAKENINGTHEIRLIFTINGSTRENGTH&AILURE
to remove cables can result in severe
personal injury, death or substantial
property damage.
7. Proceed to “Perform hydrostatic pressure test,” page 8.
&ORBLOCKASSEMBLY
2EMOVELAGSCREWSINFRONTINREARFROMSHIPPING
rails.
2EMOVEBOILERFROMSKID#ABLESAREALREADYATTACHED
TOBLOCKASSEMBLY3EE4ABLEFORLIFTINGWEIGHT
s 5SINGCRANEnATTACHFREEEND OFCABLESTOEYEOF
crane.
s 5SING HOISTnATTACH FREE ENDOF CABLESTOHOIST
2AISEBOILEROFFSKID5SEPIPEROLLERSUNDERSTEEL
SKIDANGLESTOROLLBOILER
0LACEBOILER INFINALPOSITION#ENTERBOILERON
foundation, if used.
,EVELBOILER3HIMUNDERSKIDANGLESIFNECESSARY
#UTOFFCABLES
#ABLESARENOT INTENDED FORLONGTERM
USAGE#ABLESMAYCORRODEINSIDEBOILER
WEAKENINGTHEIRLIFTINGSTRENGTH&AILURE
to remove cables can result in severe
personal injury, death or substantial
property damage.
)NSPECTBLOCKASSEMBLYFORDISJOINTEDSECTIONS#HECK
gas-tight seal of flue collector hood and cleanout plates.
Gas tight seal must be maintained to
PREVENTPOSSIBLEFLUE GAS LEAKAGEAND
carbon monoxide emissions, resulting in
severe personal injury or death.
A #HECKINSIDESECTIONASSEMBLYFORANYLIGHTPASSING
through unsealed areas.
B -ARKALLUNSEALEDAREAS
C !TUNSEALEDAREASCHECKFOR
sDAMAGEDGASKETS
sSEALINGROPENOTINPLACE
sLOOSEBOLTSORNUTS
D #ORRECTALL CONDITIONS AND REPEATSTEPB)F
UNSEALEDAREASSTILLEXISTCONTACTYOUR7EIL-C,AIN
distributor or sales office before continuing
installation.
7. Proceed to “Perform hydrostatic pressure test,”
page 8.
4ABLE Lifting weights
Boiler model
number
Packaged boiler
lbs.
Assembled block
lbs.
380 1355 1150
480 1615 1385
580 1875 1620
680 2130 1855
780 2390 2090
880 2650 2325
980 2910 2560
1080 3165 2795
1180 3425 3030
1280 3680 3265
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
6 Part No. 550-141-935/0215
Assemble block
3
Sections are top heavy. Unbolted sections
may fall if not supported, resulting in
severe personal injury or death.
)NSTALLBACKREFRACTORYBLANKET
,AYBACKSECTIONONmOORWITHPORTSFACEUP
!PPLYADHESIVETOBLANKET
0RESSBLANKETAGAINSTBACK TARGET WALLAS SHOWN IN
Figure 4.
5SING KNIFE CUTHOLETHROUGH BLANKETTO EXPOSE
observation port opening.
0REPAREBACKSECTION
!PPLY1
/8” continuous bead of sealing rope adhesive in
sealing rope grooves. See Figure 4. $O NOT GET ANY
ADHESIVEONMACHINEDPORTSURFACES.
0LACEvSEALINGROPEINGROOVE!ROUNDCURVESGRASP
at 1” intervals and push together. Do not stretch.
Do not pre-cut rope. Gas tight seal must
be maintained to prevent possibility of
mUEGAS LEAKAGEANDCARBON MONOXIDE
emissions, causing severe personal injury
or death.
3. Remove any grit from port machined surfaces with
clean rag.
&IGURESealing rope installation &IGURESilicone sealant
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 7½” and 3½” sealing rings in appropriate port
openings. See Figure 4. If sealing ring slips out of
groove, stretch ring gently for several seconds, then
reposition in groove.
!PPLYCONTINUOUSBEADOF SILICONE SEALANT NOLARGER
than 1
/16”around entire outside edge of OUTER machined
surface of port. Refer to Figure 5. $O NOT APPLY
SILICONE SEALANT ON NEXT TO OR UNDER SEALING
RING.
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.
0OSITIONSECTIONUPRIGHTONFOUNDATIONIFUSEDAND
screw 3” pipe at least 22” long into 3” return tapping.
0LACEABLOCKUNDERPIPETOHOLDSECTIONUPRIGHT
s)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
7Part No. 550-141-935/0215
)NSTALLINTERMEDIATESECTIONS
Sections are top heavy. Unbolted sections may fall if not
supported, resulting in severe personal injury or death.
1. Remove and discard 3/8” diameter shipping tie rods.
2. R
emove 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.
0OSITIONINTERMEDIATESECTIONSOALIGNINGLUGSlTINTOSOCKETSOFNEXTSECTION
See Figure 6.
)NSTALL4) TANKLESS INTERMEDIATE AND 3)SUPPLYINTERMEDIATESECTIONS
WHENUSEDINORDERSHOWNIN4ABLE
5. Draw sections together until metal-to-metal contact is made around
MACHINEDPORTOPENINGSSEE&IGURE
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.
)MPORTANTLeave an equal amount of thread on each end
of the draw rod. This is needed to allow securing the jacket
support brackets in placeSEEPAGESAND
c. Draw rods should be torqued to a range of 90 to 100 ft. - lbs. Do not
BACKOFFDRAWRODS
d. Metal-to-metal contact will be achieved around port openings. See
&IGURE)FGAPOCCURSITSHOULDBENOGREATERTHANv#HECKWITH
feeler gauge.
e. If, for any reason, gap around machined port opening exceeds .032”,
CHECKFORROPEEXTENDINGFROMROPEGROOVESDIRTONPORTOPENINGSOR
SOCKETSORMISALIGNEDLUGS)FCORRECTIONSAREMADEANDGAPSTILLEXISTS
CONTACTYOUR7EIL-C,AINDISTRIBUTORORSALESOFlCEBEFORECONTINUING
installation.
6. !FTERERECTINGlRSTINTERMEDIATE SECTIONCHECK BOTH
sections for plumb. Failure to plumb sections can cause
misaligned piping and breeching, possibly resulting in
property damage.
2EPEATSTEPSFROMh0REPAREBACKSECTIONvPAGE
Assemble block (continued)
3
&IGURESealing ring installation and port alignment
4ABLESection arrangement
0REPAREREMAININGSECTIONS
1. Follow“Prepare intermediate section”for remaining intermediate and front
SECTIONS
a. Remove any grit from threads inside tapped holes with clean rag.
)NSTALL BOTTOM REFRACTORY BLANKET ON COMBUSTION
CHAMBERmOORINSIDESECTIONBLOCK
5NROLL BLANKET ONLY TO DEPTH OF BACKSECTIONAND FIRST INTERMEDIATE
section.
3PREADADHESIVEONBOTTOMSIDEOFBLANKET
0RESSBLANKETINTOCENTERBOTTOMOFSECTIONS
5NROLLANDINSTALLBLANKETPERSTEPSANDASEACHINTERMEDIATEANDFRONT
section are installed.
!TFRONTSECTIONCUTOFFBLANKETvFROMBURNEROPENING$ISCARDUNUSED
BLANKET
Do not use petroleum-based cleaning
or sealing compounds in boiler system.
Severe damage to system components
can result, causing substantial property
damage.
B #HECKEACHSECTIONFORPROPERSEALINGROPEPOSITION
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
LEAKAGEANDCARBONMONOXIDEEMISSIONS
resulting in severe personal injury or
death.
)FUSINGTANKLESSHEATER4)SECTIONS
)NSTALLTANKLESSHEATERSANDGASKETSORHEATERCOVERPLATES
ANDGASKETS5SE3
/8” x 3/4” studs, washers and nuts.
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
8 Part No. 550-141-935/0215
0ERFORMHYDROSTATICPRESSURETEST
0REPAREBOILERANDTEST
3EEPAGESANDFORTAPPINGLOCATIONS)NSTALL
A "OILERDRAINNOTFURNISHED
B 7ATERPRESSUREGAUGEFORTESTONLY"ESUREGAUGECANHANDLETESTPRESSURESEESTEP
C !IRVENTINUPPERTAPPING+
2. Plug remaining tappings.
Do not pressure test with any control installed. Damage to control can occur due
to overpressure.
3. Fill boiler. Vent ALLAIR0RESSURETESTATLEASTMINUTESATAPRESSURENOTLESSTHANTHEFOLLOWING
Steam BOILER
"ETWEENANDPSIG
Wa t e r BOILER
1½ tiMESMAXIMUMALLOWABLEWORKINGPRESSURE-!70STAMPEDONTHEBOILERNAMEPLATE
LOCATEDONBOILERJACKETFRONTPANEL
Do not exceed above test pressures by more than 10 psig.
$ONOTLEAVEBOILERUNATTENDED#OLDWATERlLLCOULDEXPANDANDCAUSEEXCESSIVE
pressure, resulting in severe personal injury, death or substantial property damage.
#HECKFORMAINTAINEDGAUGEPRESSUREANDLEAKS2EPAIRIFFOUND
,EAKSMUSTBEREPAIREDATONCE&AILURETODOSOCANDAMAGEBOILERRESULTINGIN
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.
4
s)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
9Part No. 550-141-935/0215
)NSTALLBURNERMOUNTINGPLATEONFRONTSECTION
)NSTALLFOURvXÐvSTUDSTOSECUREBURNERMOUNTINGPLATETOSECTION
A 4HREADANDLOCKTOGETHERTWONUTSONROUNDEDENDOFSTUD4HREADmATENDOFSTUDINTOONE
of four holes located around opening.
b. Remove nuts.
c. Repeat steps a and b for remaining studs.
)NSTALLBURNERMOUNTINGPLATE
A !PPLY1
/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. Use ½” washers and nuts.
)NSTALLOBSERVATIONPORTASSEMBLIESONFRONTANDBACKSECTIONS
)NSTALLFRONTOBSERVATIONPORTASSEMBLY
A !PPLY1
/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 5/16 “ - 18 x ¾” slotted head screws.
2EPEATABOVESTEPSFORBACKOBSERVATIONPORTASSEMBLY
)NSTALLCLEANOUTPLATES
#LEANOUTPLATESMUSTBEINSTALLEDGASTIGHTTOPREVENTPOSSIBILITYOFmUEGASLEAKAGE
and carbon monoxide emissions, resulting in severe personal injury or death.
3EE&IGURE0OSITIONTWOvXÐvCARRIAGEBOLTSINCLEANOUTOPENING3ECUREWITHWASHERSAND
nuts.
0LACEBLANKETINSULATIONPIECEAGAINSTCLEANOUTPLATE
3. Mount cleanout plate over opening. Secure with nuts and washers.
4. Repeat steps 1 through 3 for remaining cleanout plates.
#OMPLETEBLOCKASSEMBLY
5
&IGURECleanout plate assembly
The boiler contains ceramic fiber
and fiberglass materials. Use care
when handling these materials per
instructions on page 38 of this
manual. Failure to comply could
result in severe personal injury.
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
10 Part No. 550-141-935/0215
)NSTALLmUECOLLECTOR
6
&IGURECollector hood preparation
&IGUREFlue collector sealing rope installation
&LUECOLLECTORASSEMBLY
1. Figure 10, page 11, shows flue collector components
and locations. Figure 11, page 13,shows collector hoods
for all models. Follow all instructions in this manual to
ensure correct installation of the flue collector.
2. M
odel 80 boilers are available with either rear flue or
top flue. Verify that you have the correct components
for your application.You can convert a Model 80 from
rear to top or top to rear flue using a flue conversion
KITAVAILABLEFROMYOUR7EIL-C,AINDISTRIBUTOR
The flue outlet for top flue models must
be located as shown in this manual.
)NSTALLCOLLECTORHOLDDOWNBOLTS
&IGURELOWERLEFT)NSTALLACOLLECTORHOLDDOWN
bolt assembly at each section joint, and on both sides
of the boiler section assembly. Set aside the flanged nuts
for securing the collector assembly when it is ready.
2. Each hold-down bolt assembly consists of a 5
/16” x 2”
carriage bolt, flat washer, regular hex nut and a flanged
nut as shown.
0REPAREmUECOLLECTORHOODASSEMBLY
-AKESUREGASKETSAREINTACTNOTTORNOR
otherwise damaged. These conditions can
CAUSEPOSSIBLEmUEGASLEAKAGEANDCARBON
monoxide emissions, resulting in severe
personal injury or death.
The boiler contains ceramic fiber and
fiberglass materials. Use care when
handling these materials per instructions
on page 38 of this manual. Failure to
comply could result in severe personal
injury.
3TANDmUECOLLECTORHOODFRONTMODULEITEM4) on end
as in Figure 8, left side.
7IPEALLmANGEDSURFACESWITHCLEANRAG
,AYmUECOLLECTORHOODGASKETITEM) on flange.
0LACEmUECOLLECTORENDCAPITEMONGASKET!LIGN
bolt holes. Secure with seven 5/16” x 5/8” flanged bolts
and flanged nuts. 4IGHTEN TO BETWEEN AND
INCHPOUNDSTORQUE.3EE7!2.).'on page 12, top
right column.)
&OR
a. Stand remaining hood module on end, as in
Figure 8, right side.
B 7IPEALLmANGEDSURFACESWITHCLEANRAG
C ,AYGASKETONmANGE
D #AREFULLYPLACEOPENENDOFlRSTMODULEONTOPOF
GASKETALIGNINGmANGEDSURFACES
e. Secure with seven 5/16” x 5/8” flanged bolts and
flanged nuts. 4IGHTEN TO BETWEEN AND
INCHPOUNDS TORQUE. 3EE7!2.).' ONPAGE
12.)
!TTACHmATSTITCHEDSEALINGROPETOHOODASSEMBLY3EE
&IGURE
A ,AYHOODONmOORWITHmANGEDSIDEUP
B 7IPEmANGEDSURFACEWITHCLEANRAGTOREMOVEDIRT
and oil.
C !PPLYDOUBLEFACEDTAPETOmANGEDSURFACE
D !PPLYROPETOTAPEBEGINNINGONONESIDEOFOPEN
ENDOFHOODLEAVINGvEXTENDINGPASTEDGE"END
rope around corners. $/ ./4 CUT OR STRETCH
ROPE.
$ONOTPRECUTROPE!LLCOLLECTORHOOD
joints must be sealed gas-tight to prevent
POSSIBLEFLUE GASLEAKAGEAND CARBON
monoxide emissions, resulting in severe
personal injury or death.
E #ONTINUEAROUNDENTIREmANGE!TOTHEROPENEND
LEAVEvROPEEXTENDINGPASTEDGEOFmANGE#UTOFF
excess rope.
Double-faced tape serves only to hold
sealing rope in place during installation.
It will disintegrate over time. If collector
hood and sealing rope are removed for
any reason, install new tape and new
GASKET
s)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
11Part No. 550-141-935/0215
)NSTALLmUECOLLECTOR(continued)
6
&IGUREFlue collector components, typical (Model 880 collector configurations shown)
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
12 Part No. 550-141-935/0215
)NSTALLmUECOLLECTOR(continued)
6
"EFOREINSTALLINGmUECOLLECTOR
1. See Figure 10, page 11, for general assembly of flue
collector components.
2. See Figure 11, page 13 for the placement of flue collector
hoods on each model.
3. Prepare mounting holes in boiler rear section.
a. The boiler rear section has tapped holes for mounting
rear flue collector component.
b. Remove any grit from threads inside tapped holes with
clean rag.
2EARmUEBOILERSONLY
1. See Figure 10, page 11 and Figure 11, page 13.
0LACECOLLECTORHOODTRANSITIONONREARSECTION
A 7IPEITEM&IGURECOLLECTORHOOD TRANSITION
flange surfaces with a clean rag.
B !PPLYAFEWPIECESOFDOUBLEFACEDTAPEONTHECOLLECTOR
hood transition flange.
c. Place the
COLLECTORHOODTRANSITIONGASKETITEM
Figure 10) on the collector hood transition flange.
!LIGNHOLESINGASKETWITHHOLESINmANGE0RESSGASKET
firmly in place.
D 0OSITIONCOLLECTORHOODTRANSITIONONBACKOFBOILER
rear section, aligning collector hood transition flange
holes with tapped holes in boiler rear section.
e. Insert a 5/16” x 5/8” flanged bolt through the bottom
center hole and finger tighten to hold transition in
place.
f. Install six remaining bolts securing collector hood
transition to rear section. &INGERTIGHTEN only.
0LACECOLLECTORHOODASSEMBLYONSECTIONS
A #AREFULLYSETCOLLECTORHOODASSEMBLYONTOPOFSECTION
ASSEMBLY!LIGNSLOTTEDHOLESINCOLLECTORHOODmANGES
with the hold-down bolts in the sections.
b. Place the collector hood assembly so its rear flange is
AGAINSTTHECOLLECTORHOODTRANSITIONmANGEGASKET
c. Thread flanged nuts onto hold-down bolts and lNGER
TIGHTEN only.
d. Insert five 5/16” x 5/8” flanged bolts through holes in
collector hood transition and collector hood assembly
rear flange. Thread on nuts and lNGERTIGHTEN only.
4IGHTENmUECOLLECTORBOLTSANDNUTS
a. Gradually tighten all bolts and nuts on flue collector
assembly and boiler. 4IGHTENTOBETWEENAND
INCHPOUNDSTORQUE. See 7!2.).', upper right.
B !LTERNATELOCATIONSASYOUTIGHTENTHEFASTENERSTO
ensure all parts are evenly drawn down, with no gaps
or distortion of parts.
)NSTALLDAMPERANDmUECAPS
A 7IPEITEM&IGUREmUEDAMPER flange surface
with a clean rag.
B !PPLYAFEWPIECESOF DOUBLEFACED TAPE TOTHEmUE
DAMPERmANGE0OSITIONmUECOLLARGASKETONDAMPER
ANDPRESSFIRMLY IN PLACE!LIGN ALLHOLES BEFORE
securing.
c. Position flue damper assembly against collector hood
transition. Insert a #10 x ½” screw through the top
CENTERHOLE,IGHTLY TIGHTENTO HOLD mUEDAMPER IN
position.
d. Insert remaining #10 screws into flue damper flange
ANDLIGHTLYTIGHTEN!LTERNATEFROMSCREWTOSCREWAND
tighten all screws evenly and securely.
E )NSTALLmUECAPSONmUECOLLECTORTOPOPENINGSUSING
steps 5a through 5d.
4OPmUEBOILERSONLY
1. See Figure 10, page 11 and Figure 11, page 13.
0LACEREARmUECAPONREARSECTION
A 7IPEITEM&IGUREREARmUECAPGASKETSURFACEWITHACLEANRAG
B !PPLYAFEWPIECESOFDOUBLEFACEDTAPEONTHEREARmUECAPGASKETSURFACE
c. Place the
RECTANGULARGASKETITEM&IGUREONTHEmUECAPALIGNING
HOLESINGASKETWITHHOLESINREARmUECAP0RESSlRMLYINPLACE
D 0OSITIONREARmUECAPONBACKOFBOILERREARSECTIONALIGNINGREARmUECAP
holes with tapped holes in boiler rear section.
e. Insert a 5/16” x 5/8” flanged bolt through the bottom center hole and finger
tighten to hold rear flue cap in place.
f. Install six remaining bolts securing rear flue cap to rear section. &INGER
TIGHTEN only.
0LACECOLLECTORHOODASSEMBLYONSECTIONS
A #AREFULLYSETCOLLECTORHOODASSEMBLYONTOPOFSECTIONASSEMBLY!LIGNSLOTTED
holes in collector hood flanges with the hold-down bolts in the sections.
b. Place the collector hood assembly so its rear flange is against the rear flue
CAPGASKET
b. Thread flanged nuts onto hold-down bolts and lNGERTIGHTEN only.
c. Insert five 5/16” x 5/8” flanged bolts through holes in rear flue cap and
collector hood assembly rear flange. Thread on nuts and lNGERTIGHTEN only.
4IGHTENmUECOLLECTORBOLTSANDNUTS
a. Gradually tighten all bolts and nuts on flue collector assembly and boiler.
4IGHTENTOBETWEENANDINCHPOUNDSTORQUE. See 7!2.).', above.
B !LTERNATELOCATIONSASYOUTIGHTENTHEFASTENERSTOENSUREALLPARTSAREEVENLY
drawn down, with no gaps or distortion of parts.
)NSTALLDAMPERANDmUECAPSSEE&IGUREPAGE
A 7IPEITEM &IGUREmUE DAMPER flange surface and flue collector
assembly surfaces with a clean rag.
b. Position
ROUNDGASKETITEM&IGUREONmUECOLLECTORASSEMBLYin the
flue location shown in Figure 11, page 13!LIGNBOLTHOLES
C 0LACEmUEDAMPERASSEMBLYONGASKET3EE./4)#%BELOW)NSERTX
vSCREWSTHROUGHTHEHOLES!LTERNATEFROMSCREWTOSCREWANDTIGHTENALL
screws evenly and securely.
-ODELTOPmUEAPPLICATIONSALWAYSMOUNTTHEDAMPER
assembly with the damper adjustment plate pointed toward
the rear of the boiler as shown in Figure 11. Otherwise, the
JACKETTOPPANELSMAYBEDIFlCULTTOINSTALL
E )NSTALLmUECAPONREMAININGTOPOPENINGIFANYUSINGSTEPSATHROUGHC
above.
!FTERINSTALLINGmUECOLLECTOR!,,"/),%23
#HECKFORGASTIGHTSEALOFALLmUECOLLECTORHOODCOMPONENTS
!LLCOLLECTORHOODJOINTSMUSTBESEALEDGASTIGHTTOPREVENT
POSSIBLEmUE GASLEAKAGEAND CARBONMONOXIDEEMISSIONS
resulting in severe personal injury or death.
a. Open flue damper.Visually inspect inside section assembly and flue collector
assembly for any light passing through unsealed areas.
B -ARKALLUNSEALEDAREAS
C #HECKUNSEALED AREASFORCAUSE DAMAGED GASKETSSEALING ROPENOTIN
place, or loose bolts or nuts.
D #ORRECTALLCONDITIONSANDREPEATINSPECTIONPROCEDURE
e. If unsealed areas cannot be eliminated, discontinue the boiler installation.
#ONTACTYOUR7EIL-C,AINDISTRIBUTORORSALESOFlCEFORASSISTANCE
DO NOT overtighten bolts in flue collector hood assembly.
'ASKETMATERIALCOULDEXTRUDECAUSINGPOSSIBLEmUEGASLEAKAGE
and carbon monoxide emissions, resulting in severe personal
injury or death.
s)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
13Part No. 550-141-935/0215
&IGUREFlue collector components by model (see Figure 10, page 11 for flue collector components not shown below)
6)NSTALLmUECOLLECTOR(continued)
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
14 Part No. 550-141-935/0215
#ONNECTWATERBOILERPIPING
7
4ABLE ASME drain valve size
4ABLE Recommended minimum pipe sizes for
known flow rates.
4ABLE Recommended minimum pipe sizes when flow rate is
not known (see Figure 12)
&IGUREWater boiler piping, typical
:DWHUÀRZUDWH
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”
Boiler model number Valve size
380 – 480 ¾”
580 – 1180 1”
1280 1¼”
Boiler model number Supply pipe size
A
Return pipe size
B
380 2” 2”
480 2½” 2½”
580– 680 3” 3”
780–1280 4” 4”
'ENERALWATERPIPINGINFORMATION
s 3YSTEMWATER SUPPLY ANDRETURN PIPING SHOULDBE INSTALLED ANDPIPING
CONNECTIONSATTACHEDTOBOILERBEFOREERECTINGJACKETORINSTALLINGCONTROLS
s $ONOTPIPEINTHROUGHSUPPLYANDOUTTHROUGHRETURN4HISCREATESREVERSE
water flow through boiler that must not be used.
s 7HENTHREEWAYVALVESAREUSEDFORTEMPERATUREMODULATIONINSTALLSLOW
OPENINGMINIMUMMINUTEVALVESANDBOILERMIXINGPUMPTOMINIMIZE
POTENTIALOFBOILERTHERMALSHOCK3EE7-4ECH"ULLETIN3"
)NSTALLPIPING
Install piping as shown in Figure 12 for single boilers. For multiple boilers,
see Figure 13, page 15.
Improperly piped systems or undersized piping can contribute
to erratic boiler operation and possible boiler or system
damage.
#ONNECTSUPPLYANDRETURNPIPING
a. Size according to tables below.
1) For
UNKNOWNmOWRATES, size piping per Table below, using 20°F.
temperature rise through boiler.
2) For
KNOWNmOWRATES ORHIGHERmOWRATE through boiler, size
piping per Table below.
Flow at higher rates than shown in Table below for pipe size
can damage boiler, causing substantial property damage.
B ,OCATECIRCULATORINSUPPLYPIPING
c. For return piping, use full diameter pipe for 10 times that diameter
BEFOREMAKINGANYREDUCTION&OREXAMPLEAINCHRETURNSHOULDNOT
be reduced any closer to boiler return tapping than 40 inches.
D )NSTALLSYSTEMBLOWOFFDRAINVALVEINLOWESTPARTOFRETURNPIPINGCLOSE
TOBOILER!3-%MINIMUMSIZEREQUIREMENTSARESHOWNIN4ABLE
)NSTALLEXPANSIONTANK
a. #LOSEDTYPEnCONNECTTOvTAPPINGh+vREFERTOPAGESAND
5SEv.04PIPING!NYHORIZONTALPIPINGMUSTPITCHUPTOWARDTANK
at least 1 inch per each 5 feet of piping.
b. $IAPHRAGMTYPEn2EFERTOTANKMANUFACTURERSLITERATUREFORLOCATION
)NSTALLAUTOMATICAIRVENTINh+vTAPPING
C #ONNECTCOLDWATERlLLTOEXPANSIONTANKPIPING3EE&IGUREPAGE
!LSOSHOWNARERECOMMENDEDVALVESANDWATERMETERWHENUSED7ATER
METERWILLDETECTADDEDMAKEUPWATERINDICATINGLEAKSINSYSTEM
s)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
15Part No. 550-141-935/0215
#ONNECTWATERBOILERPIPING(continued)
7
0IPINGFORMULTIPLEBOILERSSEE&IGURE
ASize secondary boiler pump GPM based on
FOLLOWINGFORMULAS
#ALCULATEONLYSECONDARYPIPINGCIRCUITRESISTANCE
"OILERRESISTANCEWILL BEABOUT EQUAL TOTHREE
degree elbows of secondary pipe size. Operate each
BOILERANDITSSECONDARYPUMPFROMA7EIL-C,AIN
boiler control panel. $O NOT maintain boiler at
predetermined water temperature.
BPrimary pump GPM and head calculation should
not include secondary boiler circuits. Primary
pump can operate continuously during heating
season.
CSpace 12” maximum or as close as practical.
D #HECKVALVE
EHand valve.
%XPANSIONTANKSRELIEFVALVESANDOTHERACCESSORIES
are required but not shown.
&IGURE Multiple water boiler piping
4EMPERATURERISE, °F = 230°F – Return water temperature
'ROSSOUTPUT is in Btuh.
'0-
'ROSSOUTPUT
4EMPERATURERISEX
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
16 Part No. 550-141-935/0215
#ONNECTSTEAMBOILERPIPING
8
4ABLE Steam boiler pipe size for typical 2-pipe steam systems
'ENERALSTEAMPIPINGINFORMATION
s (ARTFORDLOOPPIPINGARRANGEMENTANDWETRETURNARE
required for steam boilers. Use the Hartford loop for
both pumped-return and gravity-return systems.
s -AINTAININCHMINIMUMFROMWATERLINETOBOTTOM
OFHEADERvFROMBOTTOMOFSECTION
s 7HENUSINGCONDENSATERECEIVERFEEDPUMPMUSTBE
energized by boiler-mounted pump controller. Install
PIPING
Install piping as shown on pages 16 through 18 for single
boilers. See page 19 for additional requirements when
piping multiple boilers.
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-
RETURNSYSTEMS!DJUSTPIPESIZING AS
needed when connecting to gravity-re-
TURNSYSTEMS#ONSULTLOCAL7EIL-C,AIN
distributor or sales office before installing
alternate piping.
#ONNECTSUPPLYANDRETURNPIPING
a. See Table 7.
1) Size condensate return piping by pump.
2) Size gravity condensate return same as equalizer
“J” pipe size.
b. Install system drain valve in lowest part of return
PIPINGCLOSETOBOILER!3-%SIZEREQUIREMENTSARE
shown in Table 6, page 14.
C #ONNECTCOLDWATERlLLPIPINGASSHOWNIN&IGURE
!LSOSHOWN ARE RECOMMENDEDVALVESAND WATER
METER IF USED7ATERMETERWILLDETECTADDED
MAKEUPWATERINDICATINGLEAKSINSYSTEM
#ONDENSATEPIPING
a. Satisfactory operation of any steam heating system
depends on adequate return of condensate to
maintain steady water level.
B !VOIDADDINGEXCESSIVEAMOUNTSOFRAWMAKEUP
water.
C 7HERE CONDENSATERETURN ISNOTADEQUATEALOW
water cutoff with pump control, condensate
receiver, and condensate boiler feed pump should
be installed. Refer to page 18, Figure 18 for piping
and Table 8 for sizing.
3. Multiple steam boiler piping
a. See page 19.
&IGURE Cold water fill piping
Figure number Boiler model
number
Riser pipe size
inches
Note 1
“H”
Header
inches
Note 2
“J”
Equalizer
inches
ABC
15
380 3 -- -- 3 2
480 4 -- -- 4 2
580 4 -- -- 4 2 ½
16
680 3 3 -- 4 2 ½
780 4 4 -- 4 2 ½
880 4 4 -- 4 3
980 4 4 -- 6 3
17 1080-1280 4 4 4 6 3
Notes:
1. Based on ASHRAE Handbook recommendations, allowing ½ oz. pressure drop per 100 feet of pipe for dry return.
2. Based on ASHRAE Handbook recommendations, allowing 2 oz. pressure drop per 100 feet of pipe at 3.5 psig. Maintain minimum 24” height
from waterline to header.
s)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
17Part No. 550-141-935/0215
#ONNECTSTEAMBOILERPIPING(continued)
8
&IGURE Model 380 through 580 steam boiler piping — NOTE minimum 24 inches between boiler
water line and bottom of header.
&IGURE Model 680 through 980 steam boiler piping — NOTE minimum 24 inches between boiler
water line and bottom of header.
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
18 Part No. 550-141-935/0215
4ABLECondensate receiver capacity
&IGURE Condensate piping to boiler
#ONNECTSTEAMBOILERPIPING(continued)
8
&IGURE Model 1080 through 1280 steam boiler piping — NOTE minimum 24 inches between boiler water line and
bottom of header.
Boiler
model
number
AHRI
gross
output
(lbs steam
per hour)
Gallons
condensate
per hour
Minimum condensate receiver
capacity (gallons) (Note 1)
Recommended
condensate
feed pump
capacity
GPM at 15 PSI
15-minute
boiler
operation
30-minute
boiler
operation
45-minute
boiler
operation
60-minute
boiler
operation
380 278 33 11 21 31 41 1.2
480 396 48 15 29 43 58 1.6
580 515 62 19 38 56 75 2.1
680 634 76 23 46 69 92 2.6
780 753 90 28 55 82 109 3.1
880 872 105 32 63 95 126 3.5
980 991 119 36 72 108 143 4.0
1110 133 40 80 120 160 4.5
1229 148 45 89 133 178 5.0
1348 162 49 98 146 195 5.4
Note 1 — Maximum time to when condensate returns to boiler.
s)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
19Part No. 550-141-935/0215
&IGUREMultiple Steam Boiler Piping Gravity Condensate Return
#ONNECTSTEAMBOILERPIPING(continued)
8
APipe as shown for gravity return systems, connecting
point Ato the wet gravity return.
For pumped-return systems, install boiler water level
CONTROLONEACHBOILERWITHBODYMARKATLEVELINDICATED
in Figure 30 on page 30. Provide at point AEITHER
s 3EPARATEFEED PUMPS ANDCHECKVALVESFOREACH
boiler, or . . .
s 3INGLEFEEDPUMPWITHSEPARATESOLENOIDVALVEFOR
each boiler.
BFor 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
TRAPINSKIMTAPPINGSEEPAGE#ONNECTTRAPSTO
condensate receiver.
Gravity-return systems are self-levelling if the wet
returns are piped to the common system wet return.
C )NSTALLBOILERPIPINGASSHOWNINTHISMANUALPAGES
through 19).
D )NSTALLSTOPVALVESPER!3-%CODEREQUIREMENTS
For pump-return systems, if using automatic steam
valves, use only slow-opening automatic valves. Use
A7EIL-C,AIN"OILER#ONTROL3YSTEMSUCHASA"#0
panel) to open each steam valve automatically before
firing burner.
E #ONSTRUCTCOMMONSUPPLYDROPHEADERWITHPIPESIZE
at least same size as largest boiler header size.
F 5SE
s !7EIL-C,AIN"OILER #ONTROL3YSTEMSUCHAS
A"#0 PANELWITH HEADERMOUNTEDPRESSURE
CONTROLSTOSEQUENCEBOILERSOR
s !STEAMPRESSURECONTROLLER
GInstall drip line in common supply drop header.
'RAVITYRETURN0IPEDRIPLINETOWETRETURN
0UMPEDRETURN5SECOMBINATIONmOATANDTHERMOSTATIC
trap and drain to condensate receiver.
Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners
20 Part No. 550-141-935/0215
)NSTALLJACKET
9
"EFOREINSTALLINGJACKET
0ACKAGEDBOILERS
s )NSTALLTOPJACKETPANELS PERINSTRUCTIONS INTHIS
manual.
.ONPACKAGEDBOILERS
s &OLLOWTHEINSTRUCTIONSINTHISSECTIONTOINSTALLALL
JACKETPANELS
s -AKE SURE THE FOLLOWING ARE COMPLETEDBEFORE
INSTALLINGJACKET
s "OILERHYDROSTATICALLYPRESSURETESTED3EEPAGE
s 0LUGSFOR UNUSED TAPPINGSINSTALLED 3EE CONTROL
tapping table, page 28 or 29.
s 3UPPLYANDRETURNPIPING INSTALLED3EEPAGES
through 19.
s #LEANOUTPLATESmUECOLLARANDmUECOLLECTORHOOD
installed. See pages 9 through 13.
4HESEPARTSMUSTBEONBOILER
s PLUGSFORUNUSEDTAPPINGS
s SUPPLYANDRETURNPIPING
s STEAMSUPPLYHEADER
s CLEANOUTPLATES
s TANKLESSHEATERSWHENUSED
s TANKLESSHEATERCOVERPLATESWHENUSED
s TANKLESSHEATERPIPINGWHENUSED
s mUEDAMPERASSEMBLY
s mUECOLLECTORHOOD
s OBSERVATIONPORTASSEMBLIES
4HESEPARTSMAYBEONBOILER
s BURNERMOUNTINGPLATE
s BURNER
4HESEPARTSMUSTBEOFFBOILER
s WATERORSTEAMGAUGE
s LIMITCONTROL
s LOWWATERCUTOFF
s GAUGEGLASSANDGAUGEGLASSCOCKS
s TRICOCKS
s DRAINCOCK
The boiler contains ceramic fiber and
fiberglass materials. Use care when
handling these materials per instructions
on page 38 of this manual. Failure to
comply could result in severe personal
injury.
2EMOVEJACKETPARTSFROMCARTONS
,OCATEJACKETCARTONS
2EMOVEJACKETPARTSFROMCARTONSASNEEDED,EAVEIN
cartons as long as possible to avoid damage.
)NSTALLSUPPORTBRACKETSANDRAILS
0LACEUPPERANDLOWERSUPPORTBRACKETSOVERDRAWRODS
as shown in Figure 20, page 21.
2. Fasten securely with 5
/8” nuts where shown.
Models 380, 480, 580, 680 and 780 do
NOTREQUIRELOWERSUPPORTBRACKETS/NLY
UPPERBRACKETSAREREQUIRED
3PACETHEBRACKETSALONGTHELENGTHOFTHEBOILERSOTHERE
are close to an equal number of sections on either side
OFTHEBRACKETS
!TTACHTHEUPPERANDLOWERRAILSONEACHSIDEOFTHE
boiler by securing with #10 x ½” Phillips pan head
screws. $/./4 tighten the screws more than finger-
tight.
)NSTALLJACKETFRONTANDREARPANELS
!TTACHTHE FRONTANDREARJACKETPANELSTOTHEUPPER
and lower channels using #10 x ½” Phillips pan head
screws, as shown in Figure 20.
2. 2EAR mUE BOILERS ONLY REMOVE REARJACKETPANEL
mUECOLLECTORTRANSITIONKNOCKOUTWITHTINSNIPSBEFORE
installing on boiler.
This manual suits for next models
9
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