Weil-McLain 88 User manual

Part No. 550-100-068/1009
for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners
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.
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.
For additional
information, refer to . .
Burner
specification and
data sheets
for burners pre-tested
with model 88 boilers
s)NSTALLATION
s3TARTUP
s-AINTENANCE
s0ARTS
Boiler Manual
Water & steam boilers – Series 2
88

Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
2 Part No. 550-100-068/1009
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 CANCAUSESEVERE 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 before proceeding:
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 sub-
stantial property damage.
0ROPANEBOILERSONLY — Your propane supplier mixes an odorant
with the propane to make its presence detectable. In some instances,
the odorant can fade and the gas may no longer have an odor.
N Propane gas can accumulate at floor level. Smell near the floor for
the gas odorant or any unusual odor. If you suspect a leak, do not
attempt to light the burner.
N Use caution when attempting to light a propane burner (or pilot
burner). This should be done by a qualified service technician,
particularly if flame outages (or pilot outages) are common.
N Periodically check the odorant level of your gas.
N Inspect boiler and system at least yearly to make sure all gas piping
is leak-tight.
N Consult your propane supplier regarding installation of a gas leak
detector. There are some products on the market intended for
this purpose. Your supplier may be able to suggest an appropriate
device.
Read before proceeding

"OILERMANUALs)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
3Part No. 550-100-068/1009
"EFOREINSTALLINGBOILER4
3ETBOILERINPLACE                        7
!SSEMBLINGTHEBLOCK                       8
0ERFORMHYDROSTATICPRESSURETEST               11
#OMPLETEBLOCKASSEMBLY                   12
#ONNECTWATERBOILERPIPING                  14
#ONNECTSTEAMBOILERPIPING                  16
)NSTALLJACKET                        20
0IPETANKLESSHEATERS                     25
)NSTALLWATERBOILERCONTROLS                  26
)NSTALLSTEAMBOILERCONTROLS                  27
#ONNECTBREECHINGANDVENTINGSYSTEMS           29
)NSTALLBURNERWIRINGANDlLLSYSTEM            31
)NSTALLFUELPIPING                        32
-AKElNALADJUSTMENTS                    33
(ANDLINGCERAMIClBERANDlBERGLASSMATERIALS34
2ATINGS                              35
$IMENSIONS                          36
0ARTS38
Contents

Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
4 Part No. 550-100-068/1009
Installation must comply with —
State, provincial and local plumbing, heating and electrical1.
codes.
Regulations of servicing utilities.2.
ASME Section IV, Low Pressure Boiler and Pressure Vessel Code.3.
National Fuel Gas Code, ANSI/NFPA 54, when applicable.4.
National codes where applicable.5.
Before selecting boiler location
Check for nearby connections to:1.
Fuel supply.a.
Electrical power.b.
System water or steam piping.c.
Venting systems - seed. page 29.
Combustion and ventilation air supply — seee. page 5.
Check area around boiler. Remove any combustible materials,2.
gasoline and other flammable vapors and liquids.
Failure to keep boiler area clear and free of combustible
materials, gasoline and other flammable liquids and
vapors can result in severe personal injury, death and
substantial property damage.
Provide clearance around boiler
Provide minimum clearances to combustible materials:1.
"OILERTOPs — 24 inches.
"OILERFRONTs — 48 inches.
"OILERmUEs — 9 inches.
"OILERREARs — 9 inches.
"OILERSIDESs — 6 inches.
3INGLEWALLVENTPIPEs – 18 inches.
$OUBLEWALLVENTPIPEs – refer to vent pipe manufacturer's
recommendations for vent pipe clearances.
Boiler may be installed on combustible flooring.2.
See3. page 36 for boiler dimensions.
Flue pipe/breeching clearances take precedence over
jacket clearances.
Provide minimum clearances for servicing:4.
,EFT SIDEs — for cleaning and tankless heater removal –
39 inches.
2EARs — for breeching — 36 inches.
Allow sufficient space on remaining sides for cleaning, servicings
and burner installation. See burner literature for length and
recommended service clearances.
Lay a foundation, if needed
Floor construction and condition must be suitable for weight of1.
boiler when filled with water. See page 35 for approximate boiler
operating weight.
A level concrete or brick foundation, constructed per2. Figure 1 and
Figure 2 is required when:
A floor could possibly become flooded.a.
Non-level conditions exist.b.
Before installing boiler
Boiler foundation, when required&IGURE
Boiler foundation (see&IGURE Figure 1)
"OILERMODEL
NUMBER ,ENGTHLMINIMUM
(inches)
488 33
588 41
688 49
788 57
888 65
988 73
1088 81
1188 89
1288 97
1388 105
1488 113
1588 121
1688 129
1788 137
1888 145

"OILERMANUALs)NSTALLATIONs3TART5Ps-AINTENANCEs0ARTS
5Part No. 550-100-068/1009
Before installing boiler (continued)
Combustion and ventilation air openings
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.
Do not install an exhaust fan in boiler room. Incor-
rect burner operation can result.
When combustion and ventilation air enters
through side wall openings, ensure that the open-
ings comply with the requirements of Figure 3 and
Figure 4.
Opening sizes must comply with state, provincial
or local codes. In the absence of local requirements,
use the National Fuel Gas Code, ANSI/NFPA 54).
The following information is taken from ANSI/
NFPA 54. For details and information not addressed
below, refer to the standard.
Combustion air openings to inside
2EQUIREDVOLUMEOFINTERIORSPACES
ANSI/NFPA 54 allows combustion air to be supplied through openings
to interior spaces IFTHEVOLUMEOFTHECONNECTEDINTERIORSPACES
MEETSTHEMINIMUMVOLUMEREQUIREDBYTHESTANDARD.
The minimum volume of interior spaces can be taken as 50 cubic feet
per 1,000 Btuh of all appliances in the spaces, or the minimum volume
can be calculated using the formulas given in ANSI/NFPA 54. Excep-
tion: If the air infiltration rate for the spaces is known to be less than
0.40 air changes per hour, the minimum volume must be calculated
as specified in the standard.
)NSIDEAIROPENINGSIZESANDLOCATIONS
For spaces that provide the minimum volume required by ANSI/
NFPA 54, the air openings must be sized per the following:
#OMBININGSPACESONTHESAMESTORYEach opening shall have
a minimum free area of 1 in2/1000 Btuh (2200 mm2/kW) of the total
input rating of all appliances in the space but not less than 100 in2
(0.06 m2). One opening shall commence within 12 inches (300 mm)
of the top, and one opening shall commence within 12 inches (300
mm) of the bottom, of the enclosure. The minimum dimension of air
openings shall be not less than 3 inches (80 mm).
#OMBININGSPACESINDIFFERENTSTORIESThe volumes of spaces
in different stories shall be considered as communicating spaces where
such spaces are connected by one or more openings in doors or floors
having a total minimum free area of 2 in2/1000 Btuh (4400 mm2/kW)
of total input rating of all appliances.
Combustion and ventilation air openings&IGURE — Boiler room below grade
Combustion and ventilation air openings&IGURE — Boiler room partially or completely
above grade
Combustion air openings to
outside
Outdoor combustion air can be taken through per-
manent openings (TWO or ONE), as described in the
following. The minimum dimension of air openings
shall not be less than 3 inches (80 mm).
Outside openingsTWOPERMANENTOPENINGS
METHOD
Two permanent openings, one commencing within
12 inches (300 mm) of the top and one commencing
within 12 inches (300 mm) of the bottom of the enclo-
sure shall be provided. The openings shall communicate
directly, or by ducts, with the outdoors or spaces that