Well-mcLain 3 Series User manual

Boiler Manual
!
WARNING
Installation and service of the boiler must be performed by a qualied installer or service technician.
Read all instructions, including this manual and all other information shipped with the boiler, before
installation or operation. Perform steps in the order given. Failure to comply could result in severe
personal injury, death or substantial property damage.
88
Water Boiler - Series 3
For use with Gas, Light Oil, and Gas
with Light Oil Fired Burners
Manual Part Number 550-100-572/0123

2550-100-572/0123
 88  3 
Contents
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Abbreviations . . . . . . . . . . . . . . . . . . . . . . 3
- 
Safety Signals . . . . . . . . . . . . . . . . . . . . . . 5
Please Read Before Proceeding . . . . . . . . . . . . 5
Servicing a Boiler. . . . . . . . . . . . . . . . . . . . . . . .5
Boiler Operation . . . . . . . . . . . . . . . . . . . . . . . .6
Boiler Water . . . . . . . . . . . . . . . . . . . . . . . . . .6
Commonwealth of Massachusetts . . . . . . . . . . . . . . .6
Freeze Protection Fluids . . . . . . . . . . . . . . . . . . . .6
Damage from Water Contact . . . . . . . . . . . . . . . . . .6
Frozen Water Damage . . . . . . . . . . . . . . . . . . . . .6
- 
Prepare Boiler Location. . . . . . . . . . . . . . . . . 7
Installation Compliance Requirements . . . . . . . . . . . . .7
Checks Before Boiler Installation. . . . . . . . . . . . . . . .7
Flooring and Foundation . . . . . . . . . . . . . . . . . . . .8
Garage Installation . . . . . . . . . . . . . . . . . . . . . . .8
Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . .8
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Prepare the Boiler . . . . . . . . . . . . . . . . . . . 10
Removing a Packaged Boiler from the Crate. . . . . . . . . 10
Removing a Preassembled Block from the Crate . . . . . . 11
Boiler Assembly . . . . . . . . . . . . . . . . . . . . 12
Assembling the Block. . . . . . . . . . . . . . . . . . . . . 12
Perform Hydrostatic Pressure Test . . . . . . . . . . . . . . 15
Complete the Block Assembly . . . . . . . . . . . . . . . .16
Damper Connector Installation . . . . . . . . . . . . . . . . 18
Connect Water Boiler Piping . . . . . . . . . . . . . 20
General Water Piping Information . . . . . . . . . . . . . . 20
Install Water Piping . . . . . . . . . . . . . . . . . . . . . . 20
Bypass Circulator Sizing . . . . . . . . . . . . . . . . . . .21
Install the Jacket. . . . . . . . . . . . . . . . . . . . 22
Preparing for Jacket Installation . . . . . . . . . . . . . . . 22
Removal of Jacket Parts . . . . . . . . . . . . . . . . . . .22
Install Support Brackets and Channels. . . . . . . . . . . . 22
Install the Jacket Front and Back Panels. . . . . . . . . . . 24
Install Jacket Side Panels . . . . . . . . . . . . . . . . . . 24
Install Top Insulation . . . . . . . . . . . . . . . . . . . . . 26
Install Jacket Top Panels . . . . . . . . . . . . . . . . . . . 26
Install Jacket Trim . . . . . . . . . . . . . . . . . . . . . . 26
Tankless Heaters . . . . . . . . . . . . . . . . . . . 28
Hot Water Precautions . . . . . . . . . . . . . . . . . . . .28
Piping Tankless Heaters . . . . . . . . . . . . . . . . . . .28
Water Boiler Controls . . . . . . . . . . . . . . . . . 29
Installing the Controls . . . . . . . . . . . . . . . . . . . . 29
Condensate Trap . . . . . . . . . . . . . . . . . . . 30
Condensate Drain Trap Construction. . . . . . . . . . . . . 30
Commonwealth of Massachusetts Installations. . . . . 32
Venting and Combustion Air - General. . . . . . . . 33
Code Compliance . . . . . . . . . . . . . . . . . . . . . . 33
Combustion Air Contamination . . . . . . . . . . . . . . . . 33
Dual Fuel Venting Requirements . . . . . . . . . . . . . . . 33
Venting and Combustion Air Options . . . . . . . 34
Existing Category I Vent System . . . . . . . . . . . . . . .34
Test Procedure for Existing Vent System. . . . . . . . . . . 34
Room Air Openings . . . . . . . . . . . . . . . . . . 35
Combustion Air Provision. . . . . . . . . . . . . . . . . . . 35
Sizing Combustion Air Openings . . . . . . . . . . . . . . . 35
Special Considerations . . . . . . . . . . . . . . . . . . . . 35
Gas Venting Requirements — Category II . . . . . . 37
Using a Chimney . . . . . . . . . . . . . . . . . . . . . . .37
Vent Piping Materials . . . . . . . . . . . . . . . . . . . . . 37
Gas Venting Requirements — General. . . . . . . . 38
General Gas Venting Information. . . . . . . . . . . . . . . 38
Engineered Vent System . . . . . . . . . . . . . . . . . . . 38
Types of Gas Venting Systems . . . . . . . . . . . . . . . . 39
Oil Venting Requirements. . . . . . . . . . . . . . . 40
Using a Chimney . . . . . . . . . . . . . . . . . . . . . . .40
Vent Piping Materials . . . . . . . . . . . . . . . . . . . . . 40
General Oil Venting Information . . . . . . . . . . . . . . . 41
Engineered Vent System . . . . . . . . . . . . . . . . . . . 41
Types of Oil Venting Systems . . . . . . . . . . . . . . . . 42
Install Burner and Fill the System . . . . . . . . . . 43
Burner Installation . . . . . . . . . . . . . . . . . . . . . . 43
Wire the Burner and Boiler Controls . . . . . . . . . . . . .43
Water Treatment . . . . . . . . . . . . . . . . . . . . . . .44
Freeze Protection (when used). . . . . . . . . . . . . . . . 44
Fill the Water Boiler System . . . . . . . . . . . . . . . . . 44
Fuel Piping . . . . . . . . . . . . . . . . . . . . . . . 45
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . .45
Fuel Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . 46
Final Adjustments . . . . . . . . . . . . . . . . . . . 47
Adjust the Burner and Damper Assembly . . . . . . . . . . 47
Check the Boiler for Gas-Tight Seal . . . . . . . . . . . . .47
- 
Maintenance - General . . . . . . . . . . . . . . . . 49
Handling Ceramic Fiber Materials . . . . . . . . . . . . . . 49
Perform Startup and Checkout . . . . . . . . . . . . . . . . 49
Annual Inspection . . . . . . . . . . . . . . . . . . . 50
General Inspection Information. . . . . . . . . . . . . . . . 50
Inspect the Boiler Area . . . . . . . . . . . . . . . . . . . .50
Inspect All Piping for Leaks. . . . . . . . . . . . . . . . . . 50
Inspect the Boiler Interior . . . . . . . . . . . . . . . . . . . . . . 50
Check Air Openings . . . . . . . . . . . . . . . . . . . . . 50
- 
Ordering . . . . . . . . . . . . . . . . . . . . . . . . 51
Replacement Parts . . . . . . . . . . . . . . . . . . 52
Dimensions . . . . . . . . . . . . . . . . . . . . . . 54
- 
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . 57
Maintenance Log . . . . . . . . . . . . . . . . . . . 58
Installation and Service Certicate. . . . . . . . . . 59
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

3550-100-572/0123
88  3  
Tools Needed Purpose
1/16" at blade screwdriver Wiring onto terminal blocks.
Phillips head screwdriver Jacket posts and channels
5/16" wrench or socket Sight glass
11 mm wrench or socket Cover plate bolts
3/4" wrench or socket Burner mounting plate
15/16" wrench or socket Castings to castings tie rod nuts
1-1/16" wrench or socket Limit control
9/16" wrench Pressure and temperature gauge
Flat head screwdriver Sight glass
Pipe wrench Water piping and plugs
Multimeter Measurement readings on sensors
and electrical components
Manometer
(inclined or digital)
Measuring the gas pressure
coming to the boiler
Combustion analyzer
(digital preferred) Combustion testing
Contact thermometer Checking surface temperatures of
the heat exchanger and pipes
Abbreviation Description
AHRI Air-Conditioning, Heating, and
Refrigeration Institute
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
AWG American Wire Gauge
BTUH British Thermal Unit per Hour
CFM Cubic Feet Per Minute
CO Carbon Monoxide
CO2Carbon Dioxide
CP Consumer Protection
HX Heat Exchanger
LWCO Low Water Cut-O󰀨
MAWP Maximum Allowable Working Pressure
MBH Thousands of Btuh
NFPA National Fire and Protection Agency
NIOSH National Institute for Occupational Safety
and Health
W.C. Water Column

Table 2 Common abbreviationsTable 1 Common tools needed
Tools

4550-100-572/0123
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5550-100-572/0123
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This section is intended to provide safety information
for installers and users.
Section Contents
Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . .5
Please Read Before Proceeding . . . . . . . . . . . . . . . .5

The following dened terms are used throughout this
manual to bring attention to the presence of hazards
or other important information.
DANGER
!
Danger indicates the presence of hazards that
will result in severe personal injury, death, or
substantial property damage.
!
WARNING
Warning indicates the presence of hazards that
can result in severe personal injury, death, or
substantial property damage.
CAUTION
!
Caution indicates the presence of hazards that
will or can result in minor personal injury or
property damage.
NOTICE
Notice indicates additional information that may be
related to property damage, but is not related to
personal injury.
IMPORTANT
Important indicates additional information that is
important, but is not related to personal injury or
property damage.

!
WARNING
Adhere to all following guidelines and
instructions in this section. Failure to adhere to
these guidelines can result in severe personal
injury, death, or substantial property damage.
Installer: Read all instructions, including this manual
and all other information shipped with the boiler,
before installation. Perform steps in the order given.
Consider piping and installation when determining
boiler location.
User: This manual is for use only by a qualied
heating installer or service technician. A qualied
service technician should inspect and service this
boiler at least once per year.
Write the Consumer Protection (CP) number and
serial number in the space provided on the Installation
and Service Certicate on page 59. The CP number
can be found on the boiler jacket.
Please include the boiler model number, CP
number, and serial number when calling or writing
about the boiler. The model number can be found on
the boiler rating label.
IMPORTANT
Any claims for damage or shortage in shipment
must be led immediately against the transportation
company by the consignee.
Servicing a Boiler
• To avoid electric shock, disconnect all electrical
supplies to the boiler before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
• This boiler contains ceramic ber and berglass
materials. Refer to the warning and instructions on
page 49.



6550-100-572/0123
 88  3 
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
Boiler Operation
• Do not block ow of combustion or ventilation air
to boiler.
• Should overheating occur, or gas supply fail to
shut o󰀨, do not turn o󰀨 or disconnect electrical
supply to pump. Shut o󰀨 the gas supply at a
location external to the appliance.
Boiler Water
• Since the heat exchanger is made of cast iron,
the water chemistry must be checked. The system
pH must be in the range of 7.0 to 8.5. Chemical
treatment may be required. See page 44 for
details.
• Before connecting the boiler, thoroughly ush the
system to remove sediment. Install a strainer or other
sediment removal equipment if necessary. The cast
iron heat exchanger can be damaged by build-up or
corrosion due to sediment.
• Do not use petroleum-based cleaning or sealing
compounds in the boiler system. Gaskets and seals
in the system may be damaged, which can result in
substantial property damage.
• Continual fresh make-up water will reduce
boiler life. Mineral buildup in the heat exchanger
reduces heat transfer, overheats the cast iron heat
exchanger, and causes failure. Addition of oxygen
carried in by make-up water can cause internal
corrosion. Leaks in the boiler or piping must be
repaired at once to prevent make-up water. Use
this boiler ONLY in a closed-loop system.
• Do not add cold water to a hot boiler. Thermal
shock can cause the heat exchanger to crack.
Commonwealth of Massachusetts
When the boiler is installed within the Commonwealth
of Massachusetts:
• This product must be installed by a licensed
plumber or gas tter.
• If antifreeze is used, a reduced pressure back-ow
preventer device shall be used.
See page 32 for sidewall vent air installations.
Freeze Protection Fluids
NEVER use automotive or standard glycol antifreeze.
Use antifreeze specically made for hydronic
systems; inhibited propylene glycol is recommended.
See page 44 for more information. Thoroughly
clean and ush any replacement boiler system that
has used glycol before installing the new 88 boiler.
Damage from Water Contact
DANGER
!
DO NOT attempt to operate any boiler if any
part of the boiler, burner, or controls has been
partially or fully sprayed with or submerged
under water. The boiler must either be replaced
or completely repaired and inspected. The boiler
and all components must be in good condition
and fully reliable before operation.
If these requirements are not met, operating
the boiler will cause re, explosion, and electrical
shock hazards, leading to serious injury, death,
or substantial property damage.
Saltwater damage: The immediate e󰀨ects of
saltwater damage are like those of freshwater,
with electrical components shorting out and the
removal of critical lubricants. However, salt and other
contaminants left behind can lead to long term issues
due to the conductive and corrosive nature of salt
residue. WM Technologies equipment contaminated
with saltwater or polluted water will no longer be
covered under warranty and should be replaced.
Electrical damage: If any electrical component or
wiring has, or is suspected to have come into contact
with water, replace the boiler.
Frozen Water Damage
Power outages, unattended residences or buildings,
boiler component failures, or other electrical system
failures in cold weather could result in frozen plumbing
and water damage in a matter of hours. Consult with
a boiler contractor or a home security agent to take
preventative actions, such as installing a security
system that operates during power outages, senses
low temperature, and initiates an e󰀨ective action.

7550-100-572/0123
88  3  
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This section is intended to provide installation
instructions for qualied heating installers.
Section Contents
Prepare Boiler Location . . . . . . . . . . . . . . . . . . . .7
Prepare the Boiler . . . . . . . . . . . . . . . . . . . . . . 10
Boiler Assembly . . . . . . . . . . . . . . . . . . . . . . . 12
Connect Water Boiler Piping . . . . . . . . . . . . . . . . . 20
Install the Jacket . . . . . . . . . . . . . . . . . . . . . . .22
Tankless Heaters . . . . . . . . . . . . . . . . . . . . . . . 28
Water Boiler Controls . . . . . . . . . . . . . . . . . 29
Condensate Trap . . . . . . . . . . . . . . . . . . . 30
Commonwealth of Massachusetts Installations . . . . . 32
Venting and Combustion Air - General . . . . . . . . . . . . . . . .33
Venting and Combustion Air Options . . . . . . . . . . . . . 34
Room Air Openings. . . . . . . . . . . . . . . . . . . . . . 35
Gas Venting Requirements — Category II . . . . . . . . . . 37
Gas Venting Requirements — General. . . . . . . . . . . . 38
Oil Venting Requirements . . . . . . . . . . . . . . . . . . 40
Install Burner and Fill the System . . . . . . . . . . . . . . 43
Fuel Piping . . . . . . . . . . . . . . . . . . . . . . . . . .45
Final Adjustments. . . . . . . . . . . . . . . . . . . . . . . 47

Installation Compliance Requirements
• Local, state, provincial, and national codes, laws,
regulations, and ordinances.
• National Fuel Gas Code – ANSI Z223.1/NFPA 54,
latest edition.
• Chimneys, Fireplaces, Vents, and Solid Fuel
Burning Appliances – ANSI/NFPA 211, latest
edition.
• Installation of Oil Burning Equipment – ANSI/NFPA
31, latest edition.
• National Electrical Code – ANSI/NFPA 70, latest
edition.
• Where required by the authority having
jurisdiction, the installation must conform to the
Standard for Controls and Safety Devices for
Automatically Fired Boilers – ANSI/ASME CSD-1,
latest edition.
IMPORTANT
The 88 Series 3 water boiler met safe lighting and
other performance criteria when the boiler underwent
tests specied in UL 726 & UL 795, latest editions.
Checks Before Boiler Installation
1. Check for nearby connections to:
• System water piping
• Venting systems
• Fuel supply
• Electrical Power
• Combustion and ventilation air supply
2. Check area around boiler. Remove any
combustible materials, gasoline, and other
ammable liquids and vapors.
!
WARNING
Failure to keep boiler area clear and free of
combustible materials, gasoline, and other
ammable liquids and vapors can create an
explosion hazard, which can result in severe
personal injury, death, or substantial property
damage.
3. Check the boiler location to ensure it protects the
gas control system components from dripping
or spraying water and rain during operation or
service.
4. If a new boiler is replacing the existing boiler,
check for and correct system problems:
• System leaks causing oxygen corrosion or heat
exchanger cracks from hard water deposits.
• Incorrect expansion tank sizing.
• Lack of freeze protection in boiler water.



8550-100-572/0123
 88  3 
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Flooring and Foundation
The 88 Boiler is approved for installation on
combustible ooring, but must never be installed on
carpeting.
!
WARNING
Do not install the boiler on carpeting even if
a foundation is used. Installing a boiler on
carpeting can cause a re, which can result in
severe personal injury, death, or substantial
property damage.
1. The boiler mounting surface must be level and
suitable for the load.
2. Provide a solid foundation pad at least 4.0"
(101.6 mm) above the oor if any of the following
is true:
• Floor can become ooded.
• The oor is dirt, sand, gravel, or other loose
material.
• The boiler mounting area is severely uneven or
sloped.
3. Foundation may be brick or concrete
construction. The minimum foundation
dimensions are listed in Table 3.
4. If ooding is possible, elevate the boiler
su󰀩ciently to prevent water from reaching the
boiler.
Garage Installation
Take the following special precautions when installing
the boiler in a garage.
• Mount the boiler at a height above the oor as
specied in the latest edition of the National Fuel
Gas Code – ANSI Z223.1/NFPA 54, latest edition,
for U.S. installations.
• Locate or protect the boiler so it cannot be
damaged by a moving vehicle.
• Ensure that the installation complies with all
applicable codes.
Air Openings
Openings in oors, walls, ceilings, or roofs must be
designed for re stopping as required by local codes.
Vent pipe openings through combustible materials
must be 3/8" (9.5 mm) larger in diameter than the
vent pipe.
Air pipe openings should be 3/8" (9.5 mm) larger
in diameter than the pipe or as required by the pipe
manufacturer.
!
WARNING
Pipe openings that do not have the required
diameter can cause a re, which can result in
severe personal injury, death, or substantial
property damage.
Provide air openings for combustion air and
ventilation of the room. Follow the National Fuel Gas
Code – ANSI Z223.1/NFPA 54, latest edition for the
U.S.
Follow all applicable codes to size and verify
size of the combustion and ventilation air openings
into the space. See the Venting and Combustion
Air sections starting on page 33 for required air
openings and sizing.

Table 3 Minimum foundation dimensions
Boiler Model Minimum Dimensions (inches)
488 33 x 39 x 4
588 41 x 39 x 4
688 49 x 39 x 4
788 57 x 39 x 4
888 65 x 39 x 4
988 73 x 39 x 4
1088 81 x 39 x 4
1188 89 x 39 x 4
1288 97 x 39 x 4
1388 105 x 39 x 4
1488 113 x 39 x 4
1588 121 x 39 x 4
1688 129 x 39 x 4
1788 137 x 39 x 4
1888 145 x 39 x 4

9550-100-572/0123
88  3  
1
2
3
4
5
6
7
8
Clearances
There are minimum clearance requirements for
the boiler from combustible surfaces. There are
recommended service access clearances. See
Figure 1 for all clearances.
IMPORTANT
Without the recommended minimum clearances for
service access, it may not be possible to service the
boiler without removing it from the space.
220204
Top
Top
Left
Side
Left
Side
Edge of opening within 12 inches of floor.
Edge of opening within 12 inches of floor.
Air openings
(when required)
Air openings
(when required)
Controls end
Front
Controls end
Front
Right
Side
Right
Side
Edge of opening within 12 inches of ceiling.
Edge of opening within 12 inches of ceiling.
Rear
Rear
Ensure that the installation complies with all state, local, and applicable codes.
Clearance from:
Minimum clearances to
combustible surfaces
(inches)
Minimum allowable
service clearances
(inches)
Recommended minimum service
access clearances
(inches)
Controls end (Front) 48 48 48
Left side 6 34 39
(clean and remove tankless heater)
Right side 6 6 6
Flue 9 9 9*
Rear 9 9 36 (breeching)*
Top 24 24 24
Floor 0 0 0
Single-wall vent pipe 18 18 18
Double-wall vent pipe Refer to vent pipe manufacturer's recommendations for vent pipe clearances.
Note: Allow su󰀩cient space for cleaning, servicing, and installing the burner. See burner literature for length and recommended
service clearances.
*Flue pipe and breeching clearances take precedence over jacket clearances.
Figure 1 Clearances for 88 Boilers

10 550-100-572/0123
 88  3 
1
2
3
4
5
6
7
8

Removing a Packaged Boiler from the Crate
Leave the boiler in the crate pallet until ready to place
in the nal location. Follow all removal instructions.
IMPORTANT
Cables used for lifting are not provided by Weil-McLain.
!
WARNING
Ensure the equipment and cables used for lifting
are designed to handle the load. See Table 4
for approximate weights of section assemblies.
Failure to comply can result in severe personal
injury, death or substantial property damage.
1. Move the crate to a solid, level surface. The crate
must be sitting securely on the ground.
2. Remove the top jacket panels and set aside until
after piping installation.
3. Remove four lag screws from the shipping brackets.
4. Remove the boiler from the skid with a crane or a
hoist. See Table 4 for lifting weight.
• Crane: Hook middle of each cable to the eye of
the crane.
• Hoist: Hook middle of each cable to the hoist.
Raise boiler o󰀨 skid. Use pipe rollers under skid
angles to roll the boiler.
5. Place the boiler in the nal position. If using a
foundation, center the boiler on the foundation.
6. Level the boiler. Shim under skid angles if necessary.
7. Cut o󰀨 the cables.
!
WARNING
Cables are not intended for long-term use.
Cables may corrode inside the boiler, weakening
their lifting strength. Failure to remove cables
can result in severe personal injury, death, or
substantial property damage.
8. Proceed to page 15 and perform pressure
testing.
Boiler Model
Number
Approximate Lifting
Weight (lbs.)
Minimum Sling
Length
(from Crane Hook to
Boiler Lifting Lugs)
488 2,928 2' 6"
588 3,490 3' 0"
688 4,152 4' 0"
788 4,714 4' 6"
888 5,276 5' 0"
988 5,838 6' 0"
1088 6,400 6' 6"
1188 7,062 7' 0"
1288 7,624 8' 0"
1388 8,186 8' 6"
1488 8,748 9' 0"
1588 9,310 10' 0"
1688 9,872 10' 6"
1788 10,584 11' 0"
1888 11,146 12' 0"
Table 4 Section assembly lifting weights

11550-100-572/0123
88  3  
1
2
3
4
5
6
7
8
Leave the block assembly in the crate pallet until
ready to place in the nal location. Follow all removal
instructions.
IMPORTANT
Cables used for lifting are not provided by Weil-McLain.
!
WARNING
Ensure the equipment and cables used for lifting
are designed to handle the load. See Table 4,
page 10 for approximate weights of section
assemblies. Failure to comply can result in
severe personal injury, death or substantial
property damage.
1. Move the crate to a solid, level surface. The crate
must be sitting securely on the ground.
2. Remove four lag screws from the shipping brackets.
3. Remove the block assembly from the skid with a
crane or a hoist. See Table 4, page 10 for lifting
weight.
• Crane: Attach free end of cables to the eye of
the crane.
• Hoist: Attach free end of cables to the hoist.
Raise the block o󰀨 the skid. Use pipe rollers
under skid angles to roll the block.
4. Place the block assembly in the nal position.
If using a foundation, center the boiler on the
foundation.
5. Level the block. Shim under skid angles if necessary.
6. Cut o󰀨 the cables.
!
WARNING
Cables are not intended for long-term use.
Cables may corrode inside the boiler, weakening
their lifting strength. Failure to remove cables
can result in severe personal injury, death, or
substantial property damage.
7. Inspect the block assembly for disjointed
sections.
8. Check the gas-tight seal of the ue collector hood
and clean out plates.
a. Check inside the section assembly for any light
passing through unsealed areas.
b. Mark all unsealed areas and check for the
following:
• Damaged gaskets.
• Displaced sealing rope.
• Loose bolts or nuts.
c. Correct all conditions and repeat the previous
steps. If unsealed areas still exist, contact Tech
Services before continuing with installation.
!
WARNING
Gas-tight seal must be maintained to prevent
possible ue gas leakage and carbon monoxide
emissions. Leakage and emissions can result in
severe personal injury or death.
9. Proceed to page 15 and perform pressure
testing.
Removing a Preassembled Block from the Crate

12 550-100-572/0123
 88  3 
1
2
3
4
5
6
7
8

Assembling the Block
!
WARNING
Ensure sections are supported. Sections are top-
heavy. Unbolted sections may fall if not supported,
which can result in severe personal injury or death.
Prepare and position the back section:
1. Apply a 1/8" continuous bead of sealing rope
adhesive in the sealing rope grooves. Do not get any
adhesive on machined port surfaces. See Figure 2.
2. Place 1/2" sealing rope into the groove. When
placing the rope around curves, grasp at 1"
intervals and push together; do not stretch.
3. The silicone-coated rope must be held in place
until the adhesive hardens.
a. Apply duct tape over the rope at the corners to
hold the rope in place. Do not apply duct tape
to any machined surface. Refer to Figure 3.
b. Keep the tape on for at least one hour to
ensure a bond between the rope and adhesive.
c. Once the adhesive has hardened, remove the
duct tape before assembling sections together.
4. Cut the rope as each section is completed.
!
WARNING
Do not pre-cut rope. Gas-tight seal must be
maintained to prevent the possibility of ue gas
leakage and carbon monoxide emissions. Failure
to comply can result in severe personal injury or
death.
NOTICE
Do not use petroleum based cleaning or sealing
compounds in the boiler system, as it can result in
severe boiler damage and substantial property damage.
5. Remove any grit from port machined surfaces
with a clean rag.
6. Place 9" and 6" sealing rings in appropriate port
openings. See Figure 2. If sealing ring slips out of
groove, stretch ring gently and reposition in groove.
7. Apply continuous bead of silicone sealant no
larger than 1/16" around entire outside edge of
outer machined surface of port. Refer to Figure 4.
Do not apply silicone sealant on, next to or under
sealing ring.
NOTICE
Apply silicone sealant as specied to prevent
unburned oil vapors from coming in contact with
the sealing ring, which can result in severe boiler
damage and substantial property damage.
Cut of
f
rope even
with edges.
9" sealing ring
6" sealing
ring
220205
Sealing rope
Figure 2 Sealing rope installation
220206
Sealing ring
Sealing ring
Silicone sealant
(apply per instructions)
Silicone sealant
(apply per instructions)
Figure 3 Holding rope in place
Figure 4 Silicone sealant
220232220232
Duct tape over
rope at corners
Do not apply duct tape to any
machined surface. Adhesive
in seal pocket could damage
the seal, which can result in
severe boiler damage and
substantial property damage.

13550-100-572/0123
88  3  
1
2
3
4
5
6
7
8
Assembling the Block, continued
8. Hoist the back section upright. Temporarily screw
a 6" threaded pipe at least 36" long into the lower
(return) tapping.
9. Hoist the section and put into position.
10. Place a block under the 6-inch pipe to hold the
back section upright and plumb.
CAUTION
!
The back section must be plumb before installing
other sections to ensure correct block assembly.
11. The 6" support pipe and block can be removed
after several sections have been installed and the
assembly is stable.
Install the intermediate sections:
12. Remove and discard 3/8" diameter shipping tie
rods.
13. Remove grit from port machined surfaces with
clean rag.
14. Position the intermediate section so aligning lugs
t into sockets of next section. See Figure 5.
15. Install tankless intermediate (TI) sections (when
used) in the order shown in Table 5, page 14.
16. Draw the sections together until metal-to-metal
contact is made around machined port openings
as shown in Figure 5.
a. Oil the threads on four draw rods. Install a
washer and nut on the end to be tightened.
Use a nut only on other end.
b. Uniformly draw the sections together, starting
at the washer/nut end.
NOTICE
Leave an equal amount of thread on each end of the
draw rod; this is needed to allow securing the jacket
support brackets in place.
c. Draw rods should be torqued to a range of 100
to 120 ft-lbs. Do not back o󰀨 draw rods.
d. Metal-to-metal contact will be achieved around
port openings. See Figure 5. If gap occurs, it
should be no greater than .032". Check with a
feeler gauge.
e. If the gap around the machined port opening
exceeds .032", check for rope extending
from rope grooves, dirt on port openings or
sockets, or misaligned lugs. If corrections are
made and a gap still exists, contact your WM
Technologies distributor before continuing
installation.
NOTICE
After erecting the rst intermediate section, check
both sections for plumb. Failure to plumb sections
can cause misaligned piping and breeching, which
can result in property damage.
!
WARNING
A gas-tight seal prevents possible ue gas
leakage and carbon monoxide emission. Failure
to position sealing rope properly can cause boiler
to not seal gas-tight, which can result in severe
personal injury or death.
17. Check each section for proper sealing rope
position before proceeding to next section.
18. Install remaining intermediate sections and front
section using the same procedure in this section.
If using tankless heater (TI) sections:
• Install tankless heaters and gaskets or heater
cover plates and gaskets. Use 3/8" x 3/4" studs,
washers and nuts.
SectionSection
Elastomer
sealing ring
Alignment
lug
Socket
Metal-
to-metal
contact
220207
Silicone
sealant
Figure 5 Sealing ring installation and port alignment

14 550-100-572/0123
 88  3 
1
2
3
4
5
6
7
8

Table 5 Hydrostatic test piping connections
Boiler model
number
W = water
Max. number of
tankless heaters
Section arrangement
(All heaters must be on left side of boiler)
F= front / B= back / I= intermediate
TI = tankless intermediate
"I" can be substituted for "TI" sections
488 W 1 F • TI • I • B
588 W 2 F • TI • I • TI • B
688 W 2 F • TI • I • TI • I • B
788 W 3 F • TI • I • TI • I • TI • B
888 W 3 F • TI • I • TI • I • TI • I • B
988 W 4 F • TI • I • TI • I • TI • I • TI • B
1088 W 4 F • TI • I • TI • I • TI • I • TI • I • B
1188 W 5 F • TI • I • TI • I • TI • I • TI • I • TI • B
1288 W 5 F • TI • I • TI • I • TI • I • TI • I • TI • I • B
1388 W 6 F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • B
1488 W 6 F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • B
1588 W 7 F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • B
1688 W 7 F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • B
1788 W 8 F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • B
1888 W 8 F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • B

15550-100-572/0123
88  3  
1
2
3
4
5
6
7
8
Perform Hydrostatic Pressure Test
1. See Figure 6 for tapping locations. Install the
following:
a. Boiler drain (not furnished).
b. Water pressure gauge for test only. Be sure
the gauge can handle test pressure.
c. Air vent in the upper tapping (K).
2. Plug remaining tappings.
NOTICE
Do not pressure test with any control installed.
Damage to control can occur due to overpressure.
!
WARNING
Do not leave boiler unattended. Cold water ll
could expand and cause excessive pressure,
which can result in severe personal injury, death
or substantial property damage.
3. Fill the boiler and vent all air.
4. Pressure test at least 10 minutes at a pressure
at 1.5 times the maximum allowable working
pressure (MAWP). The MAWP is stamped on
the boiler nameplate, located on the jacket front
panel.
5. Check for maintained gauge pressure and leaks.
Repair any leaks immediately.
NOTICE
Do not exceed the above test pressure by more than
10 psig.
NOTICE
Leaks must be repaired at once. Failure to do so
can damage boiler, resulting in substantial property
damage.
NOTICE
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Using these compounds
can cause severe damage to system components,
resulting in substantial property damage.
6. Drain the boiler. Remove the air vent, boiler drain,
and gauge.
7. Remove plugs from tappings that will be used for
controls and accessories.
Figure 6 Boiler tappings
220208
FRONT
BACK
BACK
F1
F2
D1
D2
E1
E1
E2
E2
G
G
5" NPT Supply5" NPT Supply
C1
C2
A
A
KK
6" NPT Return
5" NPT Supply
5" NPT Supply
B
H
2" NPT
2" NPT
L
L
M
Legend for Figure 6
Location Size Water
A 2" High limit, Manual reset limit
B 2" Water relief valve
L 1" Not used — Plug
C1 & C2 1" Alternate low water cut-o󰀨s
C1 Combination high and low
limit control
D1 & D2 1" Firing rate temperature control (when used)
Low water cut-o󰀨s
E1 & E2 ½" —
F1 & F2 3/8" —
G ¾" Pressure and temperature gauge
H ¾" Boiler drain
K 1" Piping to compression tank or automatic air vent
M 2" —

16 550-100-572/0123
 88  3 
1
2
3
4
5
6
7
8

Complete the Block Assembly
Install the burner mounting plate onto the front
section:
1. Install four 1/2" x 3-1/2" studs to secure the
burner mounting plate to the section.
a. Thread and lock together two nuts on rounded
end of stud. Thread at 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 the burner mounting plate:
a. Apply 1/8" continuous bead of sealing rope
adhesive in groove around opening in section.
b. Position 1/2" sealing rope in groove. Where
rope ends meet in the groove, apply a
generous amount of adhesive between the
rope ends to create a complete seal.
c. Hold the rope in place until the adhesive
hardens by applying duct tape over the rope
to hold it in place. Keep the tape on for at
least one hour to ensure a bond between
the rope and adhesive. Once the adhesive
has hardened, remove the duct tape before
installing the burner mounting plate.
d. Install the burner mounting plate with the part
number and the "UP" positioned at the top.
Use 1/2" washers and nuts.
Install observation port assemblies on front and
back sections:
3. Install the front observation port assembly:
a. Apply 1/8" 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 10-32 x 3/4"
truss-head screws.
4. Repeat step 3 for the back observation port
assembly.
Insert HX-ba󰀪es:
5. Flue HX-ba󰀪es are identied by length. The
HX-ba󰀪es must be inserted through the clean out
openings as shown in Figure 7. The installation
sequence is as follows:
a. Top position – HX-ba󰀪es, 24.0" long.
b. Second position – HX-ba󰀪es, 26.0" long.
c. Third position – HX-ba󰀪es, 31.5" long.
d. Bottom position – HX-ba󰀪es, 34.0" long.
IMPORTANT
Baes will not physically t in the row directly above
each casting boss.
6. To remove ue HX-ba󰀪es to clean the boiler
ueways, grab each ba󰀪e end with pliers and pull
straight out. Clean the HX-ba󰀪es before replacing.
Figure 7 HX-ba󰀪es installation
220209220209
24.0" Length
HX-baffles (x4)
Upper Casting Boss
Upper Casting Boss
Lower Casting Boss
Lower Casting Boss
34" Length
HX-baffles (x4)
31.5" Length
HX-baffles (x2)
26.0" Length
HX-baffles (x3)

17550-100-572/0123
88  3  
1
2
3
4
5
6
7
8
Complete the Block Assembly, continued
Install the clean out plates:
!
WARNING
Clean out plates must be installed gas-tight to
prevent possibility of ue gas leakage and carbon
monoxide emissions. Failure to comply can result
in severe personal injury or death.
1. Position two 1/4" x 1-3/4" carriage bolts in the
clean out opening, between the clean out plate
bosses. Secure with washers and nuts. See
Figure 8.
2. Place a woven berglass gasket over the carriage
bolts.
3. Mount the clean out plate over the opening.
Secure with nuts and washers.
4. Repeat steps 7-8 for remaining clean out plates.
Install the draft hood collar:
5. Install 1/8" continuous bead of sealing rope
adhesive in the groove on the draft hood collar.
6. Position a 1/2" sealing rope in the groove. Where
rope ends meet in the groove, apply a generous
amount of adhesive between the rope ends to
create a complete seal.
7. Hold the rope in place until the adhesive hardens
by applying duct tape over the rope to hold it in
place. Keep the tape on for at least one hour to
ensure a bond between the rope and adhesive.
Once the adhesive has hardened, remove the
duct tape before installing the draft hood collar.
8. Mount the collar over the ueway outlet on the
back section. Secure with 1/2" x 1-1/2" hex head
cap screws and washers.
Figure 8 Clean out plate assembly
220210
Bolt & washer
Nut
Woven fiberglass
gasket
Cleanout
plate
Nut
Washer

18 550-100-572/0123
 88  3 
1
2
3
4
5
6
7
8

Damper Connector Installation
The 88 Series 3 damper connector includes a 1/2”
female threaded boss for condensate drainage of the
vent system. This drain boss must be facing directly
downward once installed to prevent possible ue gas
leakage through the condensate drain system.
Wear protective gloves to prevent injury from sharp
edges of the damper connector.
Handle the damper connector with care; it is made
with thin gauge material and can be easily dented or
damaged before installation.
CAUTION
!
The damper connector is sharp! Wear cut-resistant
gloves during installation to prevent injury.
NOTICE
Handle the damper connector with care to avoid
damage.
1. Insert the damper connector gasket from the
provided component box into the inner groove of
the damper connector. See Figure 9.
2. The outside edge and inner 1/2” lip will hold the
gasket in place during installation onto the boiler.
3. Press the gasket down into the groove until the
face of the gasket is below the height of the inner
lip. Take care when pressing the gasket into the
groove due to the sharp edges of the inner lip.
4. Line up the gasket end of the damper connector
to the exhaust outlet of the damper casting on the
rear of the boiler.
5. Press the damper connector onto the exhaust outlet,
ensuring that the inner lip of the damper connector is
inside the inner lip of the exhaust outlet.
6. Rotate the damper connector to ensure that the
drain boss on the outside of the connector is
pointed directly downward towards the oor.
7. While holding the damper connector against
the damper casting outlet, use a paint marker
or etching tool to mark the four hole locations
onto the damper casting through the four equally
spaced holes of the damper connector. See
Figure 9 and Figure 10.
Figure 9 Damper connector
Figure 10 Damper connector on the exhaust outlet
Damper connector
inner groove
Damper
connector
drain boss
220234
Four equally
spaced installation
screw holes
Four equally
spaced installation
screw holes
220235
Exhaust
outlet
Damper casting
Damper
connector
Screw holes
(x4)
Screw holes
(x4)

19550-100-572/0123
88  3  
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Damper Connector Installation, continued
8. Remove the damper connector and place it in a
safe location to ensure no damage to the thin-
gauged material
9. Use a 5/32” drill bit to drill four holes into the
damper casting at the four marked locations.
10. Return the damper connector to the damper
casting exhaust outlet ensuring that the drain
boss is pointed directly towards the oor. See
Figure 11. The damper connector holes should
line up with the marked hole-locations. Verify that
the inner lip of the damper connector is inside the
inner lip of the damper casting exhaust outlet.
!
WARNING
The drain boss on the damper connector must be
installed facing directly down to prevent possible
ue gas leakage. Failure to comply can result
in severe personal injury, death, or substantial
property damage.
11. Use a 5/16” nut driver to install four screws
from the component box to secure the damper
connector to the damper casting outlet.
12. Apply silicone caulk from the component box
to both the inside and outside protrusion points
of each screw. Ensure an air-tight joint by
completely covering both the head and tip of each
screw in silicone caulk.
Damper connector installation notes:
• Verify a tight t between the damper connector
and damper casting outlet to ensure gasket
compression, which prevents possible ue gas
leakage between the boiler and the vent system.
• Verify that the inner lip of the damper connector is
inside the inner lip of the exhaust outlet to ensure
gasket compression, which prevents possible
ue gas leakage between the boiler and the vent
system.
• Verify that each installation screw is coated at both
ends with silicone caulk, which prevents possible
ue gas leakage between the boiler and the vent
system.
Figure 11 Drain boss location
220236
Damper connector
drain installed down
towards the floor

20 550-100-572/0123
 88  3 
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General Water Piping Information
1. System water supply and return piping should be
installed and piping connections attached to the
boiler before erecting jacket or installing controls.
2. Do not pipe in through supply and out through
return. This creates reverse water ow through
the boiler that must not be used.
3. When installing piping in a system in which
return water temperature can drop below 140°F,
apply the bypass piping with bypass pump. See
page 21 for more information.
Install Water Piping
Install piping for single boilers as shown in Figure 12
and the tables in this section. For multiple boilers,
see Figure 13, page 21.
NOTICE
Improperly piped systems or undersized piping can
contribute to erratic boiler operation and possible
boiler or system damage.
1. Connect supply and return piping.
a. Size according to Table 6 for known ow rates
at less than 20°F temperature rise through the
boiler.
b. Size according to Table 7 for unknown ow
rates, using 20°F temperature rise through the
boiler.
NOTICE
Flow at higher rates than shown in the tales in this
manual for given pipe sizes can damage the boiler,
resulting in substantial property damage.
c. Locate the circulator in the supply piping.
d. For return piping, do not reduce piping until the
length is at least 10 times the pipe diameter.
For example, a 4-inch return should not be
reduced until at least 40 inches from the boiler
return tapping.
e. Install system drain valve close to the boiler
in the lowest part of the return piping. ASME
minimum size requirements are given in Table
8, page 21.
Figure 12 Typical water boiler piping
System supply
(front only)
System supply
(front only)
System return
B
220211
Cold water
fill
Manual
isolation
valve
Manual
isolation
valve
Water
meter
Check
valve
Pressure
reducing valve
(if used)
Expansion
tank
A
Table 6 Minimum pipe sizes for known ow rates
Water ow rate
(GPM)
Supply pipe size (in.)
A
Return pipe size (in.)
B
Up to 35 2.0 2.0
36–50 2.5 2.5
51–77 3.0 3.0
78–142 4.0 4.0
143–237 5.0 5.0
238–404 6.0* 6.0*
NOTICE
High temperature rise through boiler is permissible when boiler piping connections are sized per
this table. Intermittent ow at high velocities may damage any boiler.
*6-inch piping requires nipples and 5" x 6" reducing couplings (provided with 1288 through 1888
boilers only). The total pressure drop through the 1888 boiler using the nipple and reducing
coupling will not exceed .25 psi. For smaller boilers, the pressure drop will be less.
Table 7 Minimum pipe sizes when ow rate is unknown
Boiler Model Supply pipe size (in.)
A
Return pipe size (in.)
B
488 3.0 3.0
588 – 788 4.0 4.0
888 – 1188 5.0 5.0
1288 – 1888 6.0* 6.0*
Note: Pipe sizes are based on a 20°F temperature rise through the boiler. For applications with
higher ow rates (lower temperature rise), determine the ow rate and use Table 6 to size the
piping.
*6-inch piping requires nipples and 5" x 6" reducing couplings (provided with 1288 through 1888
boilers only). The total pressure drop through the 1888 boiler using the nipple and reducing
coupling will not exceed .25 psi. For smaller boilers, the pressure drop will be less.