Weil Mclain 88 Users Manual
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2015-02-02
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Part No. 550-100-068/0308
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
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. 550-100-068/0308
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 personal injury,
death or substantial property damage if ignored.
Indicates presence of hazards that personal injury,
death or substantial property damage if ignored.
Indicates presence of hazards that 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.
— 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.
■ Propane gas can accumulate at oor level. Smell near the oor for
the gas odorant or any unusual odor. If you suspect a leak, do not
attempt to light the burner.
■ Use caution when attempting to light a propane burner (or pilot
burner). This should be done by a qualified service technician,
particularly if ame outages (or pilot outages) are common.
■ Periodically check the odorant level of your gas.
■ Inspect boiler and system at least yearly to make sure all gas piping
is leak-tight.
■ 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
Boiler manual: • Installation • Start-Up • Maintenance • Parts
3Part No. 550-100-068/0308
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Contents
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
4 Part No. 550-100-068/0308
Installation must comply with —
State, provincial and local plumbing, heating and electrical 1.
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 - see d. page 29.
Combustion and ventilation air supply — see e. page 5.
Check area around boiler. Remove any combustible materials, 2.
gasoline and other ammable vapors and liquids.
Failure to keep boiler area clear and free of combustible
materials, gasoline and other ammable 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.
• — 24 inches.
• — 48 inches.
• — 9 inches.
• — 9 inches.
• — 6 inches.
• – 18 inches.
• – refer to vent pipe manufacturer's
recommendations for vent pipe clearances.
Boiler may be installed on combustible ooring.2.
See 3. page 36 for boiler dimensions.
Flue pipe/breeching clearances take precedence over
jacket clearances.
Provide minimum clearances for servicing:4.
• — for cleaning and tankless heater removal –
39 inches.
• — for breeching — 36 inches.
Allow sufficient space on remaining sides for cleaning, servicing •
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 of 1.
boiler when filled with water. See page 36 for approximate boiler
operating weight.
A level concrete or brick foundation, constructed per 2. Figure 1 and
Figure 2 is required when:
A oor could possibly become ooded.a.
Non-level conditions exist.b.
Before installing boiler
Boiler foundation, when required
Boiler foundation (see Figure 1)
L
(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
Boiler manual: • Installation • Start-Up • Maintenance • Parts
5Part No. 550-100-068/0308
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 ue gas leakage and carbon monoxide
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
Required volume of interior spaces
ANSI/NFPA 54 allows combustion air to be supplied through openings
to interior spaces
.
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.
Inside 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:
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).
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 oors
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 — Boiler room below grade
Combustion and ventilation air openings — 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 openingsTWO
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
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
6 Part No. 550-100-068/0308
freely communicate with the outdoors, as follows:
Where directly communicating with the outdoors or where •
communicating to the outdoors through vertical ducts, each
opening shall have a minimum free area of 1 in2/4000 Btuh
(550 mm2/kW) of total input rating of all appliances in the
enclosure.
Where communicating with the outdoors through horizon-•
tal ducts, each opening shall have a minimum free area of
1 in2/2000 Btuh (1100 mm2/kW) of total input rating of all
appliances in the enclosure.
Outside openingsONE
One permanent opening, commencing within 12 inches (300 mm)
of the top of the enclosure, shall be provided. The appliance shall
have clearances of at least 1 in. (25 mm) from the sides and back
and 6 inches (150 mm) from the front of the appliance. The opening
shall directly communicate with the outdoors or shall communicate
through a vertical or horizontal duct to the outdoors or spaces that
freely communicate with the outdoors and shall have a minimum free
area of the following:
(1) 1 in2/3000 Btu/hr (700 mm2 per kW) of the total input rating of
all appliances located in the enclosure, and . . .
(2) Not less than the sum of the areas of all vent connectors in the
space.
Combustion air — combination indoor and
outdoor openings
ANSI/NFPA 54 allows combustion air to be taken from a combination
of openings to outside and to interior spaces. Follow all requirements
of the standard to determine the minimum volume of interior spaces
and to calculate minimum sizes of openings.
Engineered Installations
Engineered combustion air installations shall provide an adequate sup-
ply of combustion, ventilation, and dilution air and shall he approved
by the authority having jurisdiction.
Mechanical Combustion Air Supply
Where all combustion air is provided by a mechanical air supply
Before installing boiler (continued)
system, the combustion air shall be supplied from
outdoors at the minimum rate of 0.35 ft3/minute per
1000 Btuh (0.034 m3/min per kW) for all appliances
located within the space.
Where exhaust fans are installed in the building, •
additional air shall be provided to replace the
exhausted air.
Each of the appliances served shall be inter-•
locked to the mechanical air supply system to
prevent main burner operation where the me-
chanical air supply system is not in operation.
Where combustion air is provided by the build-•
ing’s mechanical ventilation system, the system
shall provide the specified combustion air rate
in addition to the required ventilation air.
Louvers, Grilles, and Screens.
The required size of openings for combustion, venti-
lation, and dilution air shall be based on the
of each opening.
Where the free area through a design of louver or grille
or screen is known, it shall be used in calculating the size
opening required to provide the free area specified.
Where the louver and grille design and free area are not
known, it shall be assumed that wood louvers will have
25 percent free area, and metal louvers and grilles will
have 75 percent free area.
Non-motorized louvers and grilles shall be fixed in the
open position.
Minimum screen mesh size
Screens shall not be smaller than ¼ inch mesh.
Motorized louvers
Motorized louvers shall be interlocked with the appli-
ance so they are proven in the full open position prior
to main burner ignition and during main burner opera-
tion. Means shall be proved to prevent the main burner
from igniting should the louver fail to open during
burner startup, and to shut down the main burner if
the louvers close during burner operation.
Boiler manual: • Installation • Start-Up • Maintenance • Parts
7Part No. 550-100-068/0308
Set boiler in place
Section assembly lifting weights
(pounds)
(from crane hook to
boiler lifting lugs)
488 2928 2' 6"
588 3490 3' 0"
688 4152 4' 0"
788 4714 4' 6"
888 5276 5' 0"
988 5838 6' 0"
1088 6400 6' 6"
1188 7062 7' 0"
1288 7624 8' 0"
1388 8186 8' 6"
1488 8748 9' 0"
1588 9310 10' 0"
1688 9872 10' 6"
1788 10,584 11' 0"
1888 11,146 12' 0"
Ensure the equipment and cables used for lifting are
designed to handle the load. See Figure 5 for approximate
weights of model 88 section assemblies. Failure to comply
can result in severe personal injury, death or substantial
property damage.
For packaged boiler:
Remove top jacket panels. Set aside until after boiler is piped.1.
The boiler contains ceramic fiber and fiberglass materials.
Use care when handling these materials per instructions
on "Handling ceramic fiber and fiberglass materials,"
page 34 of this manual. Failure to comply could result
in severe personal injury.
Remove lag screws (2 in front, 2 in rear) from shipping rails.2.
Remove boiler from skid. Cables are already attached to block as-3.
sembly. See Figure 5 for lifting weight.
Using crane — hook middle of each cable to eye of crane.•
Using hoist — hook middle of each cable to hoist. Raise boiler •
off skid. Use pipe rollers under skid angles to roll boiler.
Place boiler in final position. Center boiler on foundation, if 4.
used.
Level boiler. Shim under skid angles, if necessary.5.
Cut off cables.6.
Cables are not intended for long-term usage. Cables may
corrode inside boiler, weakening their lifting strength.
Failure to remove cables can result in severe personal
injury, death or substantial property damage.
Proceed to 7. "Perform hydrostatic pressure test," page 11.
For block assembly:
Remove lag screws (2 in front, 2 in rear) from shipping rails.1.
Remove boiler from skid. Cables are already attached to block as-2.
sembly. See Figure 5 for lifting weight.
• Usingcrane–attachfreeendofcablestoeyeofcrane.
• Usinghoist–attachfreeendofcablestohoist.Raiseboileroffskid.
Use pipe rollers under steel skid angles to roll boiler.
Place boiler in final position. Center boiler on foundation, if 3.
used.
Level boiler. Shim under skid angles, if necessary.4.
Cut off cables.5.
Cables are not intended for long-term usage. Cables may
corrode inside boiler, weakening their lifting strength.
Failure to remove cables can result in severe personal
injury, death or substantial property damage.
Inspect block assembly for disjointed sections. Check gas-tight seal 6.
of ue collector hood and cleanout plates.
Gas tight seal must be maintained to pre-
vent possible ue gas leakage and carbon
monoxide emissions, resulting in severe
personal injury or death.
Check inside section assembly for any light a.
passing through unsealed areas.
Mark all unsealed areas.b.
At unsealed areas, check for:c.
Damaged gaskets.•
Sealing rope not in place.•
Loose bolts or nuts.•
Correct all conditions and repeat step b. If un-d.
sealed areas still exist, contact your Weil-McLain
distributor or sales office before continuing
installation.
Proceed to 7. "Perform hydrostatic pressure test,"
page 11.
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
8 Part No. 550-100-068/0308
Assembling the block
Sections are top heavy. Unbolted sections may fall
if not supported, resulting in severe personal injury
or death.
Prepare and position back section
Apply 1. 1
/8" continuous bead of sealing rope adhesive in sealing rope
grooves. See Figure 6.
.
Place ½" sealing rope in groove. Around curves, grasp at 1" intervals 2.
and push together. Do not stretch.
Do not pre-cut rope. Gas tight seal must be maintained
to prevent possibility of ue gas leakage and carbon
monoxide emissions, causing severe personal injury or
death. Cut rope as each section is completed.
Remove any grit from port machined surfaces with clean rag.3.
Do not use petroleum-based cleaning or sealing com-
pounds in boiler system. Severe damage to system
components can result, causing substantial property
damage.
Place 9" and 6" sealing rings in appropriate port openings. See 4.
Figure 6. If sealing ring slips out of groove, stretch ring gently for
several seconds, then reposition in groove.
Apply continuous bead of silicone sealant no larger than 5. 1
/16"
around entire outside edge of machined surface of port.
Refer to Figure 7.
.
Silicone sealant applied as specified above prevents un-
burned oil vapors from coming in contact with sealing
ring. Vapor contact can damage rings, resulting in severe
damage to boiler and substantial property damage.
Hoist back section upright. Then temporarily screw a 6-inch 6.
threaded pipe at least 36 inches long into the lower (return) tap-
ping.
Hoist the section and put into position.7.
Place a block under the 6-inch pipe to hold the back section up-8.
right and plumb.
The back section must be plumb before installing other
sections to ensure the block will assemble correctly.
The 6-inch support pipe and block can be removed after several 9.
sections have been installed, and the assembly is stable.
Install intermediate sections as described on the following page.10.
Sealing rope installation
Silicone sealant
Boiler manual: • Installation • Start-Up • Maintenance • Parts
9Part No. 550-100-068/0308
Sections are top heavy. Unbolted sections may fall
if not supported, resulting in severe personal injury
or death.
Install intermediate sections
Remove and discard 1. 3/8" diameter shipping tie rods.
Remove grit from port machined surfaces with clean rag.2.
Do not use petroleum-based cleaning or sealing com-
pounds in boiler system. Severe damage to system
components can result, causing substantial property
damage.
Position intermediate section so aligning lugs fit into sockets of 3.
next section. See Figure 8.
Install TI (tankless intermediate) and SI (supply intermediate) 4.
sections (when used) in order shown in Figure 9, page 10.
Draw sections together until metal-to-metal contact is made 5.
around machined port openings (see Figure 8):
Oil threads on 4 draw rods. Install washer and nut on end to a.
be tightened. Use nut only on other end.
Uniformly draw sections together, starting at washer/nut b.
end.
Important — 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. The draw rods must not
extend past the face of the front or back section, or they
will interfere with the jacket.
Draw rods should be torqued to a range of 90 to 100 ft-lbs. Do c.
not back off draw rods.
Metal-to-metal contact will be achieved around port openings. d.
See Figure 8. If gap occurs, it should be no greater than .032".
Check with feeler gauge.
If, for any reason, gap around machined port opening exceeds e.
.032", check for rope extending from rope grooves, dirt on port
openings or sockets, or misaligned lugs. If corrections are made
and gap still exists, contact your Weil-McLain distributor or
sales office before continuing installation.
Sealing ring installation and port alignment
Assembling the block
After erecting first intermediate section,
check both sections for plumb. Failure
to plumb sections can cause misaligned
piping and breeching, possibly resulting
in property damage.
Repeat steps 1-5.6.
Check each section for proper sealing rope position 7.
before proceeding to next section.
Failure to position sealing rope properly
can cause boiler to not seal gas-tight.
Gas tight seal prevents possible ue gas
leakage and carbon monoxide emissions,
resulting in severe personal injury or
death.
Install remaining intermediate sections and front 8.
section using the same procedure.
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.
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
10 Part No. 550-100-068/0308
Assembling the block (continued)
Section arrangement
W = water
S = steam
(all heaters must be on left side of boiler)
F = front / B = back / I = Intermediate
TI = tankless intermediate SI = supply intermediate (steam only)
"I" can be substituted for "TI" sections
488 W&S 1F • TI • I • B
588 W&S 2F • TI • I • TI • B
688 W&S 2F • TI • I • TI • I • B
788 W&S 3F • TI • I • TI • I • TI • B
888 W&S 3F • TI • I • TI • I • TI • I • B
988 W&S 4F • TI • I • TI • I • TI • I • TI • B
1088 W&S 4F • TI • I • TI • I • TI • I • TI • I • B
1188 W&S 5F • TI • I • TI • I • TI • I • TI • I • TI • B
1288 W 5F • TI • I • TI • I • TI • I • TI • I • TI • I • B
1288 S 4F • TI • I • TI • I • SI • I • TI • I • TI • I • B
1388 W 6F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • B
1388 S 6F • TI • I • TI • I • TI • SI • TI • I • TI • I • TI • B
1488 W 6F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • B
1488 S 5F • TI • I • TI • I • TI • I • SI • I • TI • I • TI • I • B
1588 W 7F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • B
1588 S 7F • TI • I • TI • I • TI • I • TI • SI • TI • I • TI • I • TI • B
1688 W 7F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • B
1688 S 7F • TI • I • TI • I • TI • SI • TI • I • TI • I • TI • I • TI • I • B
1788 W 8F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • B
1788 S 8F • TI • I • TI • SI • TI • I • TI • I • TI • SI • TI • I • TI • I • TI • B
1888 W 8F • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • TI • I • B
1888 S 6F • TI • I • TI • I • SI • I • TI • I • TI • I • SI • I • TI • I • TI • I • B
Boiler manual: • Installation • Start-Up • Maintenance • Parts
11Part No. 550-100-068/0308
Perform hydrostatic pressure test
Prepare boiler and test:
See 1. Figure 10 and Figure 11 for tapping locations. Install:
Boiler drain (not furnished).a.
Water pressure gauge — for test only. Be sure gauge can handle b.
test pressure — see step 3.
Air vent in upper tapping (K).c.
Plug remaining tappings.2.
Do not pressure test with any control installed. Damage
to control can occur due to overpressure.
Fill boiler. Vent 3. all air. Pressure test at least 10 minutes at a pressure
not less than the following:
a. boiler: .
b. boiler:
(MAWP) stamped on the boiler nameplate, located
on boiler jacket front panel.
Do not exceed above test pressures by more than 10
psig.
Do not leave boiler unattended. Cold water fill could
expand and cause excessive pressure, resulting in severe
personal injury, death or substantial property damage.
Check for maintained gauge pressure and leaks. Repair if found.4.
Leaks must be repaired at once. Failure to do so can dam-
age boiler, resulting in substantial property damage.
Do not use petroleum-based cleaning or sealing com-
pounds in boiler system. Severe damage to system
components can result, causing substantial property
damage.
Drain boiler and remove air vent, boiler drain and gauge. Remove 5.
plugs from tappings that will be used for controls and accesso-
ries.
Boiler tapping locations and sizes (see Figure 11)
A 2" Steam relief valve and/or
Skim tapping
High limit
Manual reset limit
B 2" Steam relief valve Water relief valve
L 1" Secondary probe LWCO Not used — Plug
C1 & C2 1" Low water cut-offs Alternate low water cut-offs
C1 — Combination high and low
limit control
D1 & D2 1" Alternate low water cut-offs Firing rate temperature
control (when used)
Low water cut-offs
E1 & E2 ½" Gauge glass —
F1 & F2 C\,"Try cock tappings —
G ¾" Pressure limit control,
Pressure operating control and
pressure gauge,
Firing rate pressure control
(when used)
Combination pressure–
temperature gauge
H ¾" Boiler drain (see Figure 17,
page page 15, for system blow-
off (drain) valve locations and
sizes
Boiler drain
K 1" — Piping to compression tank or
automatic air vent
Boiler tappings
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
12 Part No. 550-100-068/0308
Insert HXT-bars through cleanout openings as shown below (omit the bottom, blue-tipped, HXT-bar in the opening between the front section and the first intermediate section)
Complete block assembly
Install burner mounting plate on front
section
Install four ½" x 3½" studs to secure burner mounting plate to 1.
section:
Thread and lock together two nuts on rounded end of stud. a.
Thread at end of stud into one of four holes located around
opening.
Remove nuts.b.
Repeat steps a and b for remaining studs.c.
Install burner mounting plate:2.
Apply a. 1
/8" continuous bead of sealing rope adhesive in groove
around opening in section.
Position ½" sealing rope in groove. Overlap ends at least one b.
inch.
Install burner mounting plate with part number and the word, c.
"" positioned at top. Use ½" washers and nuts.
Install observation port assemblies on front
and back sections
Install front observation port assembly:1.
Apply a. 1
/8" continuous bead of sealing rope adhesive in groove
on observation port.
Position b. 3/8" sealing rope in groove.
Secure assembly to section. Use 10-32 x ¾" c.
truss-head screws.
Repeat above steps for back observation port as-2.
sembly.
Insert HXT-bars
See 1. Figure 12, page 12.
Flue HXT-bars are identified by painted ends. They 2.
must be inserted as shown, with the HXT-bars in
the sequence:
• position
• -tipped, HXT-bar 24 inches long —
place on the top row of pins.
• position
• -tipped HXT-bar, 26 inches long —
place on the first row of pins below the top
clean-out plate boss.
• position
• -tipped HXT-bar, 34 inches long —
place on the first row of pins below the
bottom cleanout plate boss.
Boiler manual: • Installation • Start-Up • Maintenance • Parts
13Part No. 550-100-068/0308
Cleanout plate assembly
Complete block assembly (continued)
The boiler contains ceramic fiber and
fiberglass materials. Use care when han-
dling these materials per instructions on
page 34 of this manual. Failure to comply
could result in severe personal injury.
DO NOT insert a bottom HXT-bar into the opening
between the FRONT section and the first intermediate
section.
To remove ue HXT-bars when required to clean the boiler 3.
ueways, grab the end of each HXT-bar with pliers and pull
straight out. Clean HXT-bars and replace as shown in Fig-
ure 12, page 12.
Install cleanout plates
Cleanout plates must be installed gas-tight to prevent
possibility of ue gas leakage and carbon monoxide
emissions, resulting in severe personal injury or death.
See 1. Figure 13.
Position two ¼" x 1¾" carriage bolts in cleanout opening, be-2.
tween the cleanout plate bosses, as shown. Secure with washers
and nuts.
Place woven fiberglass gasket over carriage bolts.3.
Mount cleanout plate over opening. Secure with nuts and wash-4.
ers.
Repeat steps 1 through 3 for remaining cleanout plates.5.
Install draft hood collar
Install 1. 1
/8" continuous bead of sealing rope adhesive in groove on
draft hood collar.
Position ½" sealing rope in groove. Overlap ends of rope at least 2.
1 inch.
Mount collar over ueway outlet on back section. Secure with ½ 3.
x 1½" hex head cap screws and washers.
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
14 Part No. 550-100-068/0308
Connect water boiler piping
General water piping information
System water supply and return piping should be installed and 1.
piping connections attached to boiler before erecting jacket or
installing controls.
Do not pipe in through supply and out through return. This creates 2.
reverse water ow through boiler that must not be used.
When installing in a system in which return water temperature can 3.
drop below 140°F, apply the by-pass piping with by-pass pump as
shown in .
Install piping
Install piping as shown in Figure 14, page 14 and Figure 18, page 15
(if applicable) for single boilers. For multiple boilers, see Fig-
ure 19, page 15.
Improperly piped systems or undersized piping can
contribute to erratic boiler operation and possible boiler
or system damage.
Connect supply and return piping:1.
Size according to tables below.a.
For • (less than 20°F
temperature rise) through boiler, see Figure 15.
For • , size piping per Figure 17,
page page 15, using 20°F temperature rise through boiler.
Flow at higher rates than shown in the tables in this
manual for given pipe sizes can damage the boiler, caus-
ing substantial property damage.
Locate circulator in supply piping.b.
For return piping, use full diameter pipe for 10 times that c.
diameter before making any reduction. For example, a 4-inch
return should not be reduced any closer to boiler return tap-
ping than 40 inches.
Install system blow-off (drain) valve in lowest part of return d.
piping close to boiler. ASME minimum size requirements are
given in Figure 17, page 15.
Install expansion tank:2.
a. – connect to 1" tapping "K" (see page 11). Use
1" NPT piping. Any horizontal piping must pitch up toward
tank at least 1 inch per each 5 feet of piping.
b. – Refer to tank manufacturer's literature for
location. Install automatic air vent in "K" tapping.
Connect cold water fill to expansion tank piping. c. Figure 14
shows typical piping when using a closed type tank. Connect
to the same location as the expansion tank connects to the
system when using a diaphragm type tank.
Also shown are recommended valves and water meter, when d.
used. Water meter will detect added make-up water, indicating
leaks in system.
Water boiler piping, typical
Recommended minimum pipe sizes for known flow rates (note 1)
A
B
2" 2"
36–50 2½" 2½"
51–77 3" 3"
78–142 4" 4"
143–237 5" 5"
238–404 6" (note 2) 6"
Note 1 High temperature rise through boiler is permissible when boiler
piping connections are sized per this table. Intermittent
flow at high velocities may damage any boiler.
Note 2 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 ¼ PSI. For smaller boilers, the
pressure drop will be less.
Boiler manual: • Installation • Start-Up • Maintenance • Parts
15Part No. 550-100-068/0308
Connect water boiler piping (continued)
Recommended minimum pipe sizes when flow rate is not known (see Figure 14, page page 14) (note 1)
A
B
488 3" 3"
4" 4"
5" 5"
6" (note 2) 6" (note 2)
Note 1 Pipe sizes are based on a 20°F temperature rise through the boiler. For applications
with higher flow rates (lower temperature rise), determine the flow rate and use
Figure 15, page page 14 to size the piping.
Note 2 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 ¼ PSI. For smaller boilers, the pressure
drop will be less.
ASME drain valve size
1"
1¼"
1½"
Piping multiple boilers
See 1. Figure 18. (Expansion tanks, relief valves and other accessories
are required, but omitted from the illustration for simplicity.)
The boiler piping circuits are referred to as the secondary circuits 2.
in the following.
The legend for 3. Figure 18 and boiler pump sizing recommenda-
tions follow:
Size boiler pump GPM based on the following:A
Calculate only secondary (boiler) piping circuit resistance. Al-c.
low for head loss through the boiler equal to three 90 degree
elbows of secondary pipe size.
Operate each boiler and its pump with a Weil-McLain boiler d.
control panel.
Size secondary (boiler) circuit piping using the ow rate ranges e.
given in Figure 17, page 15.
Primary pump GPM and head calculation should not include B
secondary boiler circuits. Primary pump can operate continuously
during heating season.
Connection to primary circuit — Space 12" maximum or as close C
as practical.
Check valve.D
Hand valve.E
By-pass piping for return water less than 140°F
By-pass circulator sizing:
Size system circulator as required. Determine GPM 1.
and head requirements.
Provide a by-pass circulator for EACH boiler. The ow 2.
rate for each by-pass circulator will be:
Flow = ¼ x (System circulator GPM) ÷ (# of boilers)
All circulators must run at the same time.3.
Example: For a 1,000,000 Btuh single boiler, with 4.
system temperature drop of 20°F:
System GPM = 1,000,000 ÷ 20 ÷ 500 = 100 GPM•
By-pass GPM = ¼ x 100 GPM = 25 GPM•
Determine by-pass circuit head loss for pipe size •
and fittings used.
In most applications, a standard booster pump should 5.
be adequate.
Multiple water boiler piping
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
16 Part No. 550-100-068/0308
Connect steam boiler piping
General steam piping information:
Hartford loop piping arrangement and wet return are required for 1.
steam boilers. Use the Hartford loop for both pumped-return and
gravity-return systems.
Maintain 24-inch minimum from waterline to bottom of header (63" 2.
from bottom of section).
When using condensate receiver, feed pump must be energized by 3.
boiler-mounted pump controller.
Install piping:4.
Install piping as shown on a. page 17 through page 18 for single boil-
ers. See page 19 for additional requirements when piping multiple
boilers.
Return pipe sizing.b.
Pumped return — Size return piping by pump.•
Gravity return — Size gravity return same as Hartford loop •
equalizer pipe size.
Drain valve — Install system drain valve in lowest part of return c.
piping close to boiler. See Figure 17, page 15, for sizing.
Cold water fill piping — Connect cold water fill piping as shown in d.
Figure 20. Also shown are recommended valves and water meter,
if used. Water meter will detect added makeup water, indicating
leaks in system.
Condensate return piping:e.
Satisfactory operation of any steam heating system depends on •
adequate return of condensate to maintain steady water level.
Avoid adding excessive amounts of raw make-up water.•
Where condensate return is not adequate, a low water cutoff •
with pump control, condensate receiver, and condensate boiler
feed pump should be installed.
See • Figure 21 for piping and Figure 22 for sizing.
Cold water fill piping
Condensate piping to boiler
Condensate receiver capacity required
Boiler
model number
I=B=R 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
488 810 97 29 58 87 116 3.2
488R 794 95 28 57 85 114 3.1
588 1084 130 39 78 117 156 4.3
688 1358 163 49 98 147 196 5.4
788 1632 195 59 117 176 234 6.5
888 1904 228 68 137 205 273 7.6
988 2170 261 78 157 235 313 8.7
988R 1991 239 72 145 217 289 8.0
1088 2452 294 88 176 265 353 9.8
1088R 2304 277 83 166 249 332 9.2
1188 2724 327 98 196 294 392 10.9
1288 3000 360 108 216 324 432 12.0
1388 3270 392 117 235 353 470 13.1
1488 3550 426 127 255 383 511 14.2
1588 3820 458 137 274 412 550 15.3
1688 4090 490 147 294 441 588 16.4
1688R 3980 478 143 287 430 574 15.9
1788 4370 524 157 314 471 629 14.5
1888 4640 557 167 334 501 668 18.6
Note 1 — Maximum time to when condensate returns to boiler — the longer the time for condensate to return, the larger the receiver must be.
Boiler manual: • Installation • Start-Up • Maintenance • Parts
17Part No. 550-100-068/0308
Connect steam boiler piping (continued)
Model 488 through 688 steam (1 riser)
Model 788 through 1188 steam (2 risers required)
Improperly piped systems or undersized piping can
contribute to erratic boiler operation and possible boiler
or system damage. Piping system must be installed as
shown, using pipe sizes shown. Pipe sizes shown are for
two-pipe, pumped-return systems. Adjust pipe sizing
as needed when connecting to gravity-return systems.
Consult local Weil-McLain distributor or sales office
before installing alternate piping.
Steam boiler piping guidelines
Minimum height of header above water line must
be 24 inches
The boiler header must always be at least
above the water line, as shown in all steam boiler piping
diagrams. Installing the pipe lower will result in increased
water carryover to the system, resulting in potential seri-
ous damage to system components and oxygen corrosion
due to excess make-up water.
Hartford loop piping for all steam boilers
You must install the system supply pipe between the equalizer 1.
elbow and the last boiler riser pipe connection to the header. This
assists in separating water from the steam as it turns upward into
the steam supply pipe.
Locate the top of the Hartford loop return nipple at least 4 inches 2.
below the water line, as shown.
Drawing legend & notes
(Figure 23 through Figure 26)
Riser pipes (one for each supply intermediate
section)
Horizontal pipes needed to offset the header
to allow for expansion and contraction of the
header
Steam supply must be located between last riser
connection and equalizer elbow
Equalizer elbow — full size or reducing
Equalizer pipe
Close nipple at Hartford loop tee to reduce water
hammer potential
Condensate return line (gravity or pumped)
Minimum 4 inches between water line and top
of Hartford loop return nipple
Boiler water line — all automatic water level
controls must be set to maintain this level
Minimum 24 inches between water line and
bottom of header
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
18 Part No. 550-100-068/0308
Connect steam boiler piping (continued)
Model 1288 through 1888 steam (3 or 4 risers required)
Drawing legend & notes
(Figure 23 through Figure 26)
Riser pipes (one for each supply intermediate section)
Horizontal pipes needed to offset the header to allow for expansion and contraction of the header
Steam supply must be located between last riser connection and equalizer elbow
Equalizer elbow — full size or reducing
Equalizer pipe
Close nipple at Hartford loop tee to reduce water hammer potential
Condensate return line (gravity or pumped)
Minimum 4 inches between water line and top of Hartford loop return nipple
Boiler water line — all automatic water level controls must be set to maintain this level
Minimum 24 inches between water line and bottom of header
Boiler manual: • Installation • Start-Up • Maintenance • Parts
19Part No. 550-100-068/0308
Multiple Steam Boiler Piping Gravity Condensate Return
Connect steam boiler piping (continued)
Pipe as shown for gravity return systems, connect-A
ing point A to the wet gravity return.
For pumped-return systems, install boiler water •
level control on each boiler with body mark at
level indicated in Figure 42, page 28. Provide at
point A either:
Separate feed pumps and check valves for each •
boiler, or . . .
Single feed pump, with separate solenoid valve •
for each boiler.
For pumped-return systems, install a combination
B
oat and thermostatic trap on each boiler to prevent
ooding of one boiler while other boiler is firing.
Install trap in skim tapping (see Figure 39, page 27).
Connect traps to condensate receiver.
Gravity-return systems are self-levelling if the wet
returns are piped to the common system wet return.
Install boiler piping as shown in the preceding pages C
of this manual.
Install stop valves per ASME code requirements.D
For pump-return systems, if using automatic •
steam valves, use only slow-opening automatic
valves. Use a Weil-McLain Boiler Control Sys-
tem (such as a BCP panel) to open each steam
valve automatically before firing burner.
Construct common supply drop header with pipe
E
size at least same size as largest boiler header size.
Use:
F
A Weil-McLain Boiler Control System (such as •
a BCP panel) with header-mounted pressure
control(s) to sequence boilers, or . . .
A steam pressure controller.•
Install drip line in common supply drop header.
G
Gravity-return: Pipe drip line to wet return.•
Pumped-return: Use combination oat and •
thermostatic trap and drain to condensate
receiver.
See page 18 for numbered
circle references.
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
20 Part No. 550-100-068/0308
Install jacket
Before installing jacket
The boiler contains ceramic fiber and fiberglass materials.
Use care when handling these materials per instructions
on page 34 of this manual. Failure to comply could result
in severe personal injury.
These parts 1. :
Plugs for unused tappings a.
Supply and return piping and steam supply header b.
Cleanout platesc.
Tankless heaters (when used), tankless heater cover plates d.
(when used), tankless heater piping (when used)
Flue damper assembly e.
Observation port assemblies f.
These parts 2. :
Burner mounting plate and burnera.
These parts 3. :
Water or steam gaugea.
Limit control and low water cutoffb.
Gauge glass and gauge glass cocks, tri-cocksc.
Drain cockd.
Remove jacket parts from cartons
Locate jacket cartons.1.
Remove jacket parts from cartons as needed. Leave in cartons as 2.
long as possible to avoid damage.
Jacket parts are in the boxes listed below:3.
Part Box label descriptions
Jacket screws (in jacket corner boxes) included in CRNR boxes
Jacket support brackets & hex nuts BKT
Jacket side support channels, upper & lower included in boxes
Jacket front/rear support channels, upper & lower
Jacket front panel
Jacket back panel
Jacket side and top panels
Jacket corners CRNR
Jacket trim
Install support brackets/channels
Place upper and lower support brackets over draw rods as shown 1.
in Figure 29, page 21. Place the brackets on the sections as given in
Figure 27. Sections are numbered from front to back.
Fasten each bracket loosely using two 5/8" nuts screwed onto the 2.
ends of the tie rods as shown.
Models 488 through 988 do not require lower support
brackets. Only upper brackets are required.
Fasten all nuts and screws loosely during assembly to
allow adjustment after all jacket frame parts are in-
stalled.
Place support brackets as listed below
Boiler Upper brackets on
sections:
Lower brackets
on sections:
488 2, 3 None
588 2, 4 None
688 2, 5 None
788 2, 6 None
888 3, 6 None
988 2, 5, 8 None
1088 3, 6, 9 6
1188 3, 6, 9 6
1288 3, 7, 10 7
1388 3, 7, 11 7
1488 3, 7, 10, 13 7
1588 2, 5, 8, 11, 14 8
1688 2, 5, 9, 12, 15 9
1788 2, 5, 9, 13, 16 9
1888 2, 6, 10, 14, 17 10
Attach the upper channels to the upper supports as 3.
shown in callouts , and , Figure 29, page 21.
Use two #10 x ½" screws at each bracket. Models
988 and larger have two-piece channels.
The side channels are labelled • A and B in Fig-
ure 29. Figure 28 gives the lengths of the side
channel parts for each model.
The channels at the boiler front and rear are •
part numbers 426400030 & 426400031, re-
spectively.
Upper and lower side channel lengths
Boiler Upper channel lengths
(inches)
Lower channel lengths
(inches)
ABAB
488 30 NA 26 NA
588 38 NA 34 NA
688 46 NA 42 NA
788 54 NA 50 NA
888 62 NA 58 NA
988 35 35 66 NA
1088 43 35 40 34
1188 43 43 40 42
1288 51 43 48 42
1388 51 51 48 50
1488 51 59 48 58
1588 59 59 56 58
1688 67 59 64 58
1788 67 67 64 66
1888 71 71 72 66
Attach the four jacket corners to the upper channels 4.
as shown in callout , Figure 29, page 21. Corner
part numbers are: 426400054 (front left), 055 (front
right), 056 (back left), and 057 (back right).
Attach the lower side, front and rear channels to 5.
the jacket corners as shown in callouts and
of Figure 29, page 21. Models 1088 and larger
have two-piece side channels. The channels are
labelled A and B in Figure 29. Figure 28 gives the
lengths of these parts for each model. Front and
rear lower channels are part numbers 426400032
and 426400033.
Boiler manual: • Installation • Start-Up • Maintenance • Parts
21Part No. 550-100-068/0308
Installing jacket support brackets, support channels and corners (piping and other components omitted for clarity)
Install jacket (continued)
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
22 Part No. 550-100-068/0308
Installing (removing) jacket front, rear and side panels
Press jacket trim down over jacket front, rear and side panels
Install jacket (continued)
Install jacket front and back panels
Slide the jacket front and back panels down over the top channels 1.
and into the bottom channels as shown in Figure 30.
Slide the upper and lower channels as needed to square up the 2.
fit.
Install jacket side panels
Remove jacket side panels from cartons.1.
Before installing side panels, square up the jacket support rails.2.
Place any of the jacket side panels on the rails as shown in •
Figure 30.
Butt the side panel against the jacket corner panel.•
Push/pull on the upper and lower channels until the fit-up of •
the side panel, corner panel and channels is square.
Place a jacket top panel in position against the jacket front panel •
to ensure the top alignment is square. Adjust the jacket support
rails forward or backward if needed for square alignment.
Tighten the 5/8-inch nuts on the upper (and lower) support •
brackets.
Tighten the screws securing the upper and lower rails to the •
support brackets.
Tighten the screws securing the front and back panels to the •
rails.
Apply all jacket side panels in the order shown in 3. Figure 32.
Remove jacket knockouts as required for tankless heaters and •
tankless heater openings.
Note that panel sequence is not important for boilers not •
equipped with tankless heater intermediate sections.
Install jacket top panels
Place jacket top panels as shown in 1. Figure 33, page 24.
Remove knockouts for riser pipes and air bleed piping (front •
section) using tin snips.
Install jacket trim
Press jacket trim down over the front and side jacket panels as 2.
shown in Figure 31.
Boiler manual: • Installation • Start-Up • Maintenance • Parts
23Part No. 550-100-068/0308
Jacket side panel placement
Install jacket (continued)
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
24 Part No. 550-100-068/0308
Jacket top panel placement
Install jacket (continued)
Boiler manual: • Installation • Start-Up • Maintenance • Parts
25Part No. 550-100-068/0308
Consumer Product Safety Commission and some
states recommend domestic hot water tempera-
ture of 130°F or less.
When installing an automatic mixing valve, se-
lection and installation comply with valve
manufacturer's recommendations and instruc-
tions.
Water heated to a temperature suitable for clothes
washing, dish washing and other sanitizing needs
will scald and cause injury.
Children, elderly, infirm or physically handi-
capped persons are more likely to be injured
by hot water. Never leave them unattended in
or near a bathtub, shower or sink. Never allow
small children to use a hot water faucet or draw
their own bath. If anyone using hot water in the
building fits this description, or if state laws or
local codes require certain water temperatures at
hot water faucets, take special precautions:
— Install automatic mixing valve set according
to those standards.
— Use lowest practical temperature setting.
— Check water temperature immediately after
first heating cycle and after any adjustment.
To pipe tankless heaters:
See 1. Figure 35.
Size piping no smaller than heater inlet and out-2.
let.
Automatic mixing valve must be installed. See 3.
Figure 35. Follow manufacturer's instructions to
install.
Flow regulating valve must be installed. Size accord-4.
ing to continuous draw of heater. See Figure 34.
Follow manufacturer's instructions to install.
Operating control with small adjustable differen-5.
tial scale is recommended. Install in temperature
control tapping in heater plate.
Multiple tankless heaters (see 6. Figure 35):
Use cold water supply header with individual a.
risers to each heater. Size header by increasing
one pipe size for each additional heater.
Use hot water outlet header with individual b.
risers to each heater. Size header by increasing
one pipe size for each additional heater.
Do not pipe multiple heaters in series.c.
In hard water areas, soften cold domestic water 7.
supply to heaters to prevent lime build-up.
Tankless heater ratings (Weil-McLain
ratings)
820 8.5 6.5 ¾"
Note 1 GPM based on 40–140°F DHW with boiler water
at 200°F
Note 2 Based on continuous draw with no recovery period
Tankless Heater Piping
Pipe tankless heaters
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
26 Part No. 550-100-068/0308
Install water boiler controls
Install controls:
Install furnished controls per 1. Figure 36 and Figure 37.
Failure to properly install, pipe and wire boiler controls
can result in severe damage to boiler, building and per-
sonnel; and is not covered by boiler warranty.
Relief valve must be installed with spindle in vertical position. Use 2.
fittings provided with boiler. Do not make any other connection
in that piping.
Relief valve discharge line must be piped using rigid
material suitable for 375°F, threaded one end, near oor
close to drain to eliminate potential of severe burns. Do
not pipe to any area where freezing could occur. Do not
plug, valve or place any obstruction in discharge line.
When installing low water cut-off3.
Must be installed if boiler is located above radiation level.a.
May be required on water boilers by certain state, local or ter-b.
ritorial codes or insurance companies.
Install low water cutoff designed for water installations where c.
shown in Figure 36 and Figure 37.
If installation is to comply with ASME installation requirements, an 4.
additional high temperature limit is needed. Purchase and install in
supply line between boiler and isolation valve or in tapping "A."
Dual limit control settings:5.
– set according to design requirements.
– at least 20° higher than low limit, 240°F maximum.
Install optional controls per control manufacturer's instructions.6.
Water control tappings (see Figure 37)
A 2" High limit
Manual reset limit
B 2" Water relief valve
L 1" Not used — plug
C1 & C2 1" Alternate low water cut-offs
C1 Combination high and low
limit control
D1 & D2 1" Firing rate temperature
control (when used)
Low water cut-offs
E1 & E2 ½" —
F1 & F2 C\,"—
G ¾" Combination pressure–temperature gauge
H ¾" Boiler drain
K 1" Piping to compression tank or automatic air vent
Water control locations
Boiler manual: • Installation • Start-Up • Maintenance • Parts
27Part No. 550-100-068/0308
Install steam boiler controls
Install controls:
Install controls where shown in 1. Figure 38 and Figure 39.
Failure to properly install, pipe and wire boiler controls
can result in severe damage to boiler, building and per-
sonnel; and is not covered by boiler warranty.
Install steam pressure operating and high limit controls and a.
pressure gauge. See Figure 38, Figure 39 and Figure 40, page 28.
Pressure limit control settings:
– set according to design requirements.
– set at least 2 psi higher than low limit, 15 psi maxi-
mum.
Relief valve must be installed with spindle in vertical position. b.
Use fittings provided with boiler. Do not make any other con-
nection in that piping.
Pipe relief valve discharge through vertical piping to at-
mosphere. Use rigid material suitable for 375°F, threaded
one end only. Install drain pan elbow to drain condensate.
Pipe near oor close to oor drain to eliminate potential
of severe burns. Do not pipe to any area where freezing
could occur. Do not plug, valve or place any obstruction
in discharge line.
Install water level controls and gauge glass per c. Figure 38,
Figure 39 and Figure 42, page 28.
Fittings for controls to be furnished by others.•
If water level control is not shown in • Figure 41, page 28,
locate casting mark on control and install per manufac-
turer's instructions.
Do not use water level controls with quick hook-up fit-
tings. Nuisance shutdowns will occur.
Steam control tappings (see Figure 39)
A 2" Steam relief valve and/or
Skim tapping
B 2" Steam relief valve
L 1" Secondary probe low water cut-off
C1 & C2 1" Low water cut-offs (see Figure 42, page 28)
C1 —
D1 & D2 1" Alternate low water cut-offs (see Figure 42, page 28)
E1 & E2 ½" Gauge glass
F1 & F2 C\,"Try cock tappings
G ¾" Pressure limit control,
Pressure operating control and pressure gauge,
Firing rate pressure control (when used)
H ¾" Boiler drain (see Figure 17, page page 15, for system
blow-off (drain) valve locations and sizes
K 1" —
Steam control locations
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
28 Part No. 550-100-068/0308
Install steam boiler controls (continued)
Steam control siphon and fittings Float-type water level control locations
Note 1 "A" Notes 1, 2 "B"
¼" —
1½" ½"
(see Note 3)
2C\," —
2" 150 ¼"
2C\," ¼"
2C\," ¼"
(see Note 3)
2" —
2" ¼"
2" ¼"
2" ¼"
(see Note 3) 1"to 1¼" —
Notes:
Other manufacturer's controls providing similar function may be used, if properly 1. located and selected.
Use low water cut-off function only. Pump controller function must only be handled 2. by the primary control.
When pump control is used with feedwater tank, install pump control on boiler and 3. make-up water feeder on tank. Use separate low water cutoff on boiler when back-
up is needed. Do not install combination low water cutoff and feeder as back-up
control on boiler. Feeder will operate before pump control operates.
Water level control locations (see Figure 41)
Boiler manual: • Installation • Start-Up • Maintenance • Parts
29Part No. 550-100-068/0308
Connect breeching and venting systems
General venting information
Model 88 boilers operate with positive overfire pressure. Adjust 1.
damper assembly (see Figure 49, page 33) during burner start-up
to achieve 0.1" W.C. positive pressure at damper sample hole.
Select type of venting system
Boiler, breeching and stub vent operate at positive pressure. Entire •
system must be gas-tight to prevent leaks. Stub vent height must be
limited to prevent negative draft with 3-foot minimum stub vent
height above roof. See Figure 44 and Figure 46.
Boiler operates with positive pressure overfire. Chimney •
provide excess draft which may require a barometric draft control
installed and set to provide minimum draft to maintain 0.1" posi-
tive pressure at ue collar. Minimum chimney height above roof
is 3 feet. See Figure 45 and Figure 47.
Construct metal breeching:
See 1. Figure 43 for minimum breeching diameter.
Select material type and thickness in compliance with local 2.
codes.
Conventional ue pipe should not be used as it could
leak ue gases and carbon monoxide emissions through
seams and joints, resulting in severe personal injury or
death.
Refer to ASHRAE Guide for chimney and breeching calculations 3.
and construction and lining.
Long horizontal breechings, excessive number of tees and
elbows or other obstructions restricting combustion gas
ow can result in possibility of condensation, ue gas
leakage and carbon monoxide emissions, causing severe
personal injury or death.
Minimum breeching diameter
Boiler
model
I=B=R
vent or liner diameter
(inches)
Boiler flue
collar
dimensions
(inches)
Forced
draft
Balanced
draft
488 10 12 10 round
588 10 15 10 round
688 12 15 10 round
788 12 18 12 round
888 14 18 12 round
988 14 18 14 round
1088 14 21 14 round
1188 16 21 14 round
1288 16 21 14 round
1388 16 24 14 round
1488 18 24 16 round
1588 18 24 16 round
1688 18 24 16 round
1788 18 24 16Z\, x 19M\, oval
1888 20 27 16Z\, x 19M\, oval
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
30 Part No. 550-100-068/0308
Connect breeching and venting systems
Stub vent – forced draft — single boiler
Conventional chimney – balanced draft with barometric draft control when
required — single boiler
Stub vent – forced draft — multiple boilers
Conventional chimney – balanced draft with barometric draft control when
required — multiple boilers
Boiler manual: • Installation • Start-Up • Maintenance • Parts
31Part No. 550-100-068/0308
Install burner & wiring and fill system
To install burner
Unpack burner.1.
Place gasket around air tube and against burner mounting ange. 2.
If sealing rope is used, apply 1/8" continuous bead of rope adhesive
around burner mounting ange and apply sealing rope to make
gas-tight seal.
Mount burner into opening in burner mounting plate.3.
Maintain gas-tight seal between burner mounting ange
and plate to prevent damage to air tube.
Level burner using burner support brackets where required.4.
Secure with furnished bolts.5.
Retain burner information packet. Keep with boiler.6.
To wire burner and boiler controls
Electric shock hazard. Can cause severe personal injury
or death if power source is not disconnected before
installing or servicing boiler and burner.
Install all wiring in compliance with:1.
National Electrical Code ANSI/NFPA 70.•
Any additional national, state, or local codes.•
Follow burner manual and wiring diagram found in burner in-2.
formation packet.
Use #14 AWG wire for operating and safety circuit wiring.3.
Where burner motor voltage differs from control voltage, supply 4.
proper voltage to each. Size fused disconnects and conductors per
National Electrical Code ANSI/NFPA 70.
Determine if water treatment is needed
(water boilers only)
Do not use petroleum-based cleaning or sealing com-
pounds in boiler system. Severe damage to system
components can result, causing substantial property
damage.
Continual make-up water will reduce boiler life. Minerals can build up
in sections, reducing heat transfer, overheating cast iron and causing
section failure.
For unusually hard water areas or low pH conditions
(less than 7.0) consult local water treatment company.
Provide a water softener for make-up water if hardness
exceeds 7 grains.
Freeze protection (when used)
(water boilers only)
Use antifreeze especially made for hydronic systems. 1.
Inhibited propylene glycol is recommended.
Do not use automotive, ethylene glycol
or undiluted antifreeze. Severe personal
injury or death can result.
50% solution provides protection to about -30°F.2.
Local codes may require back-ow preventer or 3.
actual disconnect from city water supply.
Determine quantity according to system water 4.
content. Boiler water content is listed in "Ratings,"
page 35. Percent of solution will affect sizing of heat
distribution units, circulator and expansion tank.
Follow antifreeze manufacturer's instructions.5.
To fill water boilers
Close manual air vents and drain cocks.1.
Fill to correct system pressure. Correct pressure will 2.
vary with each installation.
Starting on lowest oor, open air vents one at a 3.
time until water squirts out. Close vent. Repeat
with remaining vents.
Refill boiler to correct pressure.4.
To fill steam boilers
Do not fill (except for leakage test) until boiler is 1.
ready to be fired.
Fill to normal waterline, halfway up gauge glass.2.
Recommend boiler water pH 7.0 to 8.5.3.
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
32 Part No. 550-100-068/0308
Install fuel piping
Gas piping
In sizing the gas piping, the following factors should be consid-1.
ered:
Diameter and length of the gas supply piping.a.
Number of fittings.b.
Maximum gas consumption (including any possible future c.
expansion).
Allowable loss in gas pressure from the gas meter outlet to d.
the boiler.
Minimum inlet natural gas pressure required at manual main shut-2.
off valve — see the burner manual and material list.
Follow good piping practices.3.
Pipe joint compound (pipe dope) must be resistant to the corrosive 4.
action of liquefied petroleum gases and applied sparingly only to
the male threads of pipe joints.
A ground joint union must be installed in the piping to provide 5.
for servicing. The supply piping must include a manual shut-off
valve and sediment trap. See Figure 48.
Piping must be supported by hangers, not by the burner or its 6.
accessories.
Purge all air from the supply piping.7.
All gas piping must be tested for leaks after installation. Use soap 8.
suds mixture only.
Fuel oil piping
To prevent oil ow in case of oil line breakage:
• Useanti-syphondevicewhenanypartoftheoiltank
is above burner level.
• Use check valve in suction line on burner side of
manual shut-off valve nearest tank when top of fuel
oil tank is below burner level.
Failure to comply could result in fuel leakage or fire, caus-
ing potential severe personal injury, death or substantial
property damage.
A two-pipe fuel oil piping system is required for all installations.1.
Supply and return lines must enter tank from top, extending to 2.
within 4 to 6 inches from bottom of tank.
Use oil filter sized for fuel pump suction gear capacity.3.
Install oil filter.4.
Do not install filter outside or close to an outside wall.
Use continuous copper tubing to reduce possible piping leaks and 5.
to ensure reliable seal when oil piping is buried.
Use are fittings, not compression fittings.6.
— DO NOT USE soldered fittings. No safe
repair can be made.
Follow good piping practices.7.
Pipe joint compound (pipe dope) must be resistant 8.
to corrosive action of fuel oil. Apply sparingly only
to male threads of pipe joints.
Supply and return piping should be sized to design 9.
conditions, but not less than ½" O.D. continuous
copper tubing.
Auxiliary fuel oil pump is recommended when 10.
suction line lift exceeds 12 feet.
Install swing joints so they will tighten as buried 11.
tank settles to prevent fuel line breakage.
Where iron pipe is required by local codes, make 12.
swing joints with nipples and elbows several inches
long on both suction and return line. Locate close
to tank.
Install manual shut-off valve in suction line piping 13.
near burner and where piping enters building from
outside tank.
Pitch suction line piping toward fuel tank.14.
Provide tee and plug at highest point in suction 15.
line to release air from suction line and aid in
priming.
Gas supply piping
Boiler manual: • Installation • Start-Up • Maintenance • Parts
33Part No. 550-100-068/0308
Make final adjustments
Flue collar/damper assembly
Adjust burner and damper assembly:
Lock ue damper OPEN (1. Figure 49).
Make final burner adjustments using combustion test
equipment to assure proper operation. Do not fire boiler
without water. Sections will overheat, damaging boiler
and resulting in severe property damage.
Refer to burner manual for start-up and service.2.
Let burner advance to high fire. Heat boiler to design conditions.3.
Using combustion test equipment, adjust burner for:4.
12% (± ¼%) COa. 2 for No. 2 fuel oil, 0 smoke.
9 – 10% COb. 2 natural gas; CO in ue gas not to exceed 50 ppm
(0.01%).
c.
On some applications, if draft conditions or burner char-
acteristics cause the burner ame pattern to impinge on
the combustion chamber wall, you may notice pinging
sounds from the boiler. Adjust the burner if possible to
redirect the ame. If this does not work, contact your
boiler supplier or Weil-McLain to obtain an optional
combustion chamber kit (see page 38 for contents).
Adjust ue collar damper (5. Figure 49) to ensure 0.1" W.C. positive
pressure at test opening.
Tighten screws to secure in position.6.
Plug test opening with 1/8" plug provided with ue collar/damper 7.
assembly.
Adjust barometric draft control, when used, to design condi-8.
tions.
Repeat steps 4 through 6. Adjust as required.9.
Skim steam boilers:
Clean all newly installed steam boilers to remove oil.
Failure to properly clean can result in violent water level
uctuations, water passing into steam mains, or high
maintenance costs on strainers, traps and vents. Skim
boiler only. Do not clean old piping or leaks can occur.
Do not use petroleum-based cleaning or sealing com-
pounds in boiler system. Severe damage to system
components can result, causing substantial property
damage.
Remove 2" plug from skim tapping tapping "1. A" (see Fig-
ure 38, page 27).
Provide 2" skim piping from tapping to oor drain.2.
Raise waterline to midpoint of skim piping.3.
Fire burner to maintain temperature below steaming rate during 4.
skimming process.
Feed in water to maintain water level.5.
Cycle burner ON/OFF as needed to prevent rise in steam pres-6.
sure.
Continue skimming until discharge is clear. This may take several 7.
hours.
Drain boiler.8.
While boiler is warm, 9. , ush all inte-
rior surfaces under full pressure until drain water
runs clear.
Remove skim piping.10.
Re-insert plug at boiler skim tapping.11.
Close drain cock.12.
Fill with fresh water to normal water line.13.
Start burner and steam for 15 minutes to remove 14.
dissolved gases.
Stop burner.15.
Check traps and air vents for proper operation.16.
Check boiler for gas-tight seal:
Boiler must be sealed gas-tight to prevent
possible flue gas leakage and carbon
monoxide emissions, resulting in severe
personal injury or death.
Remove boiler jacket side and top panels.1.
The boiler contains ceramic fiber and
fiberglass materials. Use care when han-
dling these materials per instructions on
page 38 of this manual. Failure to comply
could result in severe personal injury.
Start burner. Observe all sealing points and chalk 2.
mark any not gas-tight.
To seal all chalk-marked areas:3.
Use silicone sealant on section ueways.a.
Check gaskets and sealing rope placement.b.
Reinstall all jacket panels.4.
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
34 Part No. 550-100-068/0308
Handling ceramic fiber and fiberglass materials
REMOVAL OF FRONT PLATE OR CLEANOUT PLATE MATERIALS
The burner front plate and cleanout plate gaskets contain ceramic fiber materials. Ceramic fibers can be
converted to cristobalite in very high temperature applications. The International Agency for Research
on Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from
occupational sources is carcinogenic to humans (Group 1).":
■ Avoid breathing dust and contact with skin and eyes.
• UseNIOSHcertieddustrespirator(N95).ThistypeofrespiratorisbasedontheOSHAre-
quirements for cristobalite at the time this document was written. Other types of respirators
may be needed depending on the job site conditions. Current NIOSH recommendations can be
found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH approved
respirators, manufacturers, and phone numbers are also listed on this web site.
• Wearlong-sleeved,loosettingclothing,gloves,andeyeprotection.
■ Apply enough water to the combustion chamber lining or base insulation to prevent airborne
dust.
■ Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag
for disposal.
■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thor-
oughly.
NIOSH stated First Aid.
■ Eye: Irrigate immediately.
■ Breathing: Fresh air.
REMOVAL OR INSTALLATION OF FIBERGLASS WOOL:
This product contains fiberglass jacket insulation and ceramic fiber materials in jacket insulation, burner
front plate insulation and cleanout plate gaskets. Airborne fibers from these materials have been listed
by the State of California as a possible cause of cancer through inhalation.
■ Avoid breathing dust and contact with skin and eyes.
• UseNIOSHcertieddustrespirator(N95).This typeofrespiratoris basedonthe OSHA
requirements for fiberglass wool at the time this document was written. Other types of respira-
tors may be needed depending on the job site conditions. Current NIOSH recommendations
can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH
approved respirators, manufacturers, and phone numbers are also listed on this web site.
• Wearlong-sleeved,loosettingclothing,gloves,andeyeprotection.
■ Operations such as sawing, blowing, tear out, and spraying may generate airborne fiber concentra-
tion requiring additional protection.
■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thor-
oughly.
NIOSH stated First Aid.
■ Eye: Irrigate immediately.
■ Breathing: Fresh air.
Boiler manual: • Installation • Start-Up • Maintenance • Parts
35Part No. 550-100-068/0308
Ratings
Boiler
model
number
I=B=R
burner
capacity
Gross
I=B=R
output
Net I=B=R ratings Boiler
H.P.
Combustion
efficiency
Thermal
efficiency
Net
firebox
volume
Flue
gas
volume
Positive
pressure
in firebox
Flue
outlet
diameter
Boiler
water
content
Packaged
boiler
weight
Light oil
GPH
Gas
MBH
MBH Steam
Sq. Ft
Steam
MBH
Water
MBH
Oil Gas Oil Gas Cubic
feet
CFM Inches
W.C.
Inches Gallons Pounds
Notes:
1, 10
2, 3 2, 4 5, 6 8 8 8 — — — — — — 7 9 — — —
488R 6.9 996 827 2,583 620 719 24.7 87.5 84.8 85.6 83.1 11.02 376 0.60 10 109 2860
488 7.0 1,010 839 2,621 629 730 25.1 87.5 84.8 85.6 83.1 11.02 370 0.60 10 109 2860
588 9.4 1,356 1,126 3,521 845 979 33.6 87.0 84.4 85.6 83.1 14.45 507 0.63 10 132 3340
688 11.8 1,701 1,413 4,469 1,072 1,229 42.2 86.7 84.1 85.6 83.1 18.08 639 0.65 10 155 3820
788 14.2 2,046 1,700 5,463 1,311 1,478 50.8 86.5 83.9 85.6 83.1 21.61 772 0.67 12 178 4345
888 16.6 2,382 1,987 6,427 1,543 1,728 59.4 86.3 83.7 85.6 83.1 25.14 906 0.69 12 201 4925
988R 17.2 2,482 2,062 6,671 1,601 1,793 61.6 86.2 83.7 85.6 83.1 28.67 1,031 0.70 14 224 5600
988 18.8 2,737 2,274 7,358 1,766 1,977 67.9 86.2 83.7 85.6 83.1 28.67 954 0.70 14 224 5600
1088R 20.0 2,887 2,399 7,763 1,863 2,086 71.7 86.2 83.6 85.6 83.1 32.20 1,184 0.71 14 247 6130
1088 21.5 3,082 2,561 8,283 1,988 2,227 76.5 86.2 83.6 85.6 83.1 32.20 1,101 0.71 14 247 6130
1188 23.5 3,428 2,848 9,213 2,211 2,477 85.1 86.1 83.5 85.7 83.1 35.76 1,299 0.72 14 270 6695
1288 26.0 3,773 3,135 10,147 2,434 2,726 93.7 86.0 83.5 85.7 83.1 39.26 1,443 0.73 14 293 7260
1388 28.5 4,119 3,422 11,071 2,657 2,976 102.2 86.0 84.4 85.7 83.1 42.79 1,588 0.74 14 316 7890
1488 31.0 4,464 3,709 12,000 2,880 3,225 110.8 86.0 83.4 85.7 83.1 46.32 1,735 0.75 16 339 8410
1588 33.0 4,809 3,996 12,925 3,102 3,475 119.4 85.9 83.3 85.7 83.1 49.85 1,854 0.76 16 362 9005
1688R 34.5 4,979 4,137 13,383 3,212 3,597 123.6 85.9 83.3 85.7 83.1 53.38 2,003 0.77 16 385 9525
1688 35.5 5,155 4,283 13,854 3,325 3,724 127.9 85.9 83.3 85.7 83.1 53.38 1,945 0.78 16 385 9525
1788 38.0 5,494 4,570 14,783 3,548 3,974 136.5 85.9 83.3 85.7 83.1 56.91 2,152 0.79 18 * 408 9780
1888 40.5 5,845 4,857 15,713 3,771 4,123 145.1 85.9 83.3 85.7 83.1 60.44 2,303 0.80 18 * 431 10775
See below to specify complete model number.1.
Burner input based on maximum of 2,000 feet altitude. For other 2. altitudes, consult Weil-McLain distributor/agent or sales office.
No. 2 fuel oil — Commercial Standard Spec CS75-56. Heating 3. value of oil = 140,000 Btu per gallon.
Gas pressure required at burner gas train inlet for rated burner 4. input; based on 1,000 Btu per cubic foot natural gas, specific
gravity of 0.60. Refer to burner manual for required pressure.
Gross I=B=R ratings have been determined under the I=B=R provision 5. governing forced draft boiler-burner units.
Based on average water temperature of 170°F in heat distributing 6. units.
Flue gas volume at outlet temperature.7.
Net I=B=R ratings are based on net installed radiation of sufficient 8.
quantity for the requirements of the building.
Nothing need be added for normal piping and pick-up.
Water ratings are based on a piping and pick-up allowance of 1.15.
Steam ratings are based on the following allowances: 488 – 588 =
1.333; 688 = 1.323; 788 = 1.301; 888 = 1.289; 988 – 1888 = 1.288.
An additional allowance should be made for gravity hot water systems
or for unusual piping and pick-up loads.
Consult local Weil-McLain distributor/agent or sales office.
With 0.10" W.C. positive pressure at flue collar.9.
Water boilers tested for 80 PSIG, ASME water working pressure. 10. Steam boilers tested for 15 PSIG, ASME steam working pressure.
* Flue collar connection is oval, 16Z\," x 19M\,"
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
36 Part No. 550-100-068/0308
Dimensions
Dimensions (inches)
Model A B C D E L W H
488 23 — — 10 54 ¾ 34 ¾ 30 23 C\,
588 31 — — 10 54 ¾ 42 ¾ 38 31 C\,
688 39 — — 10 54 ¾ 50 ¾ 46 39 C\,
788 47 — — 12 53 ¾ 58 ¾ 54 47 C\,
888 55 — — 12 53 ¾ 66 ¾ 62 55 C\,
988 63 — — 14 52 ¾ 74 ¾ 70 63 C\,
1088 71 — — 14 52 ¾ 82 ¾ 78 71 C\,
1188 79 — — 14 52 ¾ 90 ¾ 86 79 C\,
1288 87 39 ½ — 14 52 ¾ 98 ¾ 94 87 C\,
1388 95 47 ½ — 14 52 ¾ 106 ¾ 102 95 C\,
1488 103 55 ½ — 16 51 ¾ 114 ¾ 110 103 C\,
1588 111 63 ½ — 16 51 ¾ 122 ¾ 118 111 C\,
1688 119 47 ½ — 16 51 ¾ 130 ¾ 126 119 C\,
1788 127 31 ½ 79 ½ 16Z\," x 19M\,"
oval
51 ¾ 138 ¾ 134 127 C\,
1888 135 39 ½ 87 ½ 51 ¾ 146 ¾ 142 135 C\,
Model Supply & return tappings Burner lengths (Dimension F)
Supply tappings (No. & size) Return tappings (No. & size) Carlin Riello Power-
Flame
Beckett
Oil
Beckett
Gas
Steam Water Steam Water
488R 2 – 5" 2 – 5" 1 – 6" 1 – 6" 21 33 31 21 29
488 2 – 5" 2 – 5" 1 – 6" 1 – 6" 21 33 31 21 30
588 2 – 5" 2 – 5" 1 – 6" 1 – 6" 21 33 31 21 30
688 2 – 5" 2 – 5" 1 – 6" 1 – 6" 21 33 34 22 30
788 2 – 5" 2 – 5" 1 – 6" 1 – 6" 21 33 34 22 30
888 2 – 5" 2 – 5" 1 – 6" 1 – 6" 21 49 34 22 30
988R 2 – 5" 2 – 5" 1 – 6" 1 – 6" 21 49 34 22 30
988 2 – 5" 2 – 5" 1 – 6" 1 – 6" 26 49 34 22 30
1088R 2 – 5" 2 – 5" 1 – 6" 1 – 6" 26 49 34 22 30
1088 2 – 5" 2 – 5" 1 – 6" 1 – 6" 26 49 34 22 30
1188 2 – 5" 2 – 5" 1 – 6" 1 – 6" 26 49 39 23 30
1288 3 – 5" 2 – 5" 1 – 6" 1 – 6" 26 49 39 23 30
1388 3 – 5" 2 – 5" 1 – 6" 1 – 6" 26 49 39 23 30
1488 3 – 5" 2 – 5" 1 – 6" 1 – 6" 26 49 39 — 30
1588 3 – 5" 2 – 5" 1 – 6" 1 – 6" — 49 39 — —
1688R 3 – 5" 2 – 5" 1 – 6" 1 – 6" — 49 39 — —
1688 3 – 5" 2 – 5" 1 – 6" 1 – 6" — 49 39 — —
1788 4 – 5" 2 – 5" 1 – 6" 1 – 6" — 49 44 — —
1888 4 – 5" 2 – 5" 1 – 6" 1 – 6" — 56 44 — —
Boiler manual: • Installation • Start-Up • Maintenance • Parts
37Part No. 550-100-068/0308
Dimensions (continued)
Dimensions (see lettered dimensions on opposite page)
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
38 Part No. 550-100-068/0308
Parts
Item Description Part number
1 Front sections (8823) 316-301-210
2 Regular intermediate section (8825) 316-301-212
3 Tankless intermediate section (8826) 316-301-214
4 Back section (8828) 316-301-211
— Supply intermediate section (8824) (not shown) 316-301-213
— Section replacement kit (includes rope seals, rope adhesive and sealant for one joint) 386-300-213
5 Burner mounting plate Order for specific burner
6 & 13 Sealing rope — ½" (13 feet per joint, 7 feet for burner plate, 6 feet for flue collar) 590-735-140
7 Tankless heater, when used, number 820 590-291-909
8 Heater gasket 590-317-579
9 Heater cover plate 450-030-934
10 Draw rod 5/8"-11UNC-2A x 13" (apply to front and rear sections) 560-134-505
11 Draw rod 5/8"-11UNC-2A x 11" (apply between intermediate sections) 560-134-495
12 Draft hood collar assembly
(includes damper collar, damper, damper quadrant, locking plate, swivel, brackets and rope)
10-inch — 488 through 688a. . . . . . . . . . . . . . . . . . . . . .
12-inch — 788 and 888b. . . . . . . . . . . . . . . . . . . . . . . .
14-inch — 988 through 1388c. . . . . . . . . . . . . . . . . . . . .
16-inch — 1488 through 1688d. . . . . . . . . . . . . . . . . . . .
18-inch — 1788 and 1888e. . . . . . . . . . . . . . . . . . . . . .
Quadrant for flue collarf. . . . . . . . . . . . . . . . . . . . . . . .
Damper bladeg. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Damper locking plateh. . . . . . . . . . . . . . . . . . . . . . . . .
340-004-606
340-004-607
340-004-608
340-004-609
340-004-612
330-056-634
460-003-646
563-530-784
14 Cleanout plate 450-030-965
15 Woven fiberglass gasket for cleanout plate 590-317-305
16 & 18 Observation port assembly (includes frame, rope, gasket, plugs and sight glass)
Assemblya. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sight glass onlyb. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer gasket for sight glass (2c. Z\, x 1Z\v x Z\, inches) . . . . . . . .
383-600-099
591-419-199
590-317-580
17 Sealing rope, C\," (1 foot per observation port) 590-317-150
19 Burner mounting plate studs (½ x 3½ inches) Obtain locally
20 Cleanout plate nut, ¼" Obtain locally
21 Cap screw, ½–13 x ¾" Obtain locally
22 Observation port screw, 10–32 x 1½" Obtain locally
23 Flue collar cap screw, ½" x 1½" Obtain locally
24 Flue collar washer, ZZ\zn"Obtain locally
25 Burner mounting plate washer, ½" Obtain locally
26 Burner mounting plate nut, ½" Obtain locally
27 Draw rod nut, B\,"Obtain locally
28 Cleanout plate washer, ¼" Obtain locally
29 Cleanout plate carriage bolt, ¼" x 1¾" Obtain locally
30 HXT-bars (see Figure 12, page 12, for installation and placement details for HXT-bars)
3-flueway kit (includes 3 sets of bars)d. 2-flueway kit (includes 2 sets of bars)e.
416-400-130
416-400-131
Not shown Combustion chamber liner kit (optional) — includes ceramic fiber blanket for left side wall plus water glass adhesive — see
page 33. Consult your local Weil-McLain sales office for details.
Contact local Weil-McLain
sales office
Boiler manual: • Installation • Start-Up • Maintenance • Parts
39Part No. 550-100-068/0308
Parts (continued)
Parts
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners
40 Part No. 550-100-068/0308
Warranty
Residential & Commercial Cast Iron Boilers
Residential Water Warranty — Limited Lifetime
Residential Steam Warranty — Limited 10 Year
Commercial Warranty — Limited 10 Year
First Year — (All Residential & Commercial Cast Iron Boilers) Weil-McLain
warrants that its cast iron boilers are free from defects in material and workman-
ship for one year from date of installation. If any parts are found to be defective
from such defects, Weil-McLain will provide replacement of such defective parts.
Second Through Tenth Year — (Residential & Commercial Water/Steam)
Weil-McLain warrants that the cast iron sections of its water and steam boilers are
free from defects in material and workmanship from the date of installation for the
second through the tenth year. If, during such time, any section is found to be
defective, Weil-McLain will provide replacement of such defective section(s).
Eleventh Year and Beyond — (Residential Water Only) Weil-McLain warrants
that the cast iron sections of its residential water boilers are free from defects in
material and workmanship for the eleventh year and beyond from the date of
installation. If, during such time period, any section(s) is found to be defective,
Weil-McLain will provide replacement of such defective section(s) upon the
payment of a proportionate charge based on the time the boiler has been in
service. The proportionate charge will be equal to the appropriate percentage of
the list price of such section(s) at the time the warranty claim is made, and will be
determined as follows: 11th year-5%; 12th year-10%; 13th year-15%; 14th year-
20%; 15th year-25%; 16th year-30%; 17th year-35%; 18th year-40%; 19th year-
45%; 20th year-50%; 21st year-55%; 22nd year-60%; 23rd year-65%; 24th year-
70%; 25th year & beyond -75%.
These warranties do not cover boilers operated with combustion air contam-
inated externally by chemical vapors or with improper fuel additives, or with water
conditions which may have caused unusual deposits in the cast iron sections.
See section “For all Weil-McLain Products” for additional warranty information.
Weil-McLain Limited Warranties
NOTE: Residential warranties do not cover any residential products installed in build-
ings other than one or two family dwelling units, unless they are buildings with indi-
vidual residential products for each dwelling unit.
THE WARRANTIES DESCRIBED HEREIN ARE IN LIEU OF ALL OTHER WAR-
RANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IM-
PLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MER-
CHANTABILITY. WEIL-McLAIN EXPRESSLY DISCLAIMS AND EXCLUDES ANY
LIABILITY FOR CONSEQUENTIAL, INCIDENTAL, INDIRECT OR PUNITIVE DAM-
AGES FOR BREACH OF ANY EXPRESS WARRANTY. For prompt product war-
ranty claims, notify the installer who, in turn, will notify the Weil-McLain distributor
from whom he purchased the boiler. If this action does not result in warranty resolu-
tion, contact Weil-McLain Consumer Relations Department, 500 Blaine Street, Michi-
gan City, Indiana 46360, with details in support of the warranty claim. Alleged defec-
tive part or parts must be returned through the same trade channel in accordance
with the Weil-McLain procedure currently in force for handling returned goods for the
purpose of inspection to determine cause of failure. Weil-McLain will furnish new
part(s) to an authorized Weil-McLain distributor who, in turn will furnish the new part
(s) to the heating contractor who installed the boiler. If you have any questions about
the coverage of this warranty, contact Weil-McLain at the address above.
Indirect-Fired Water Heaters
Residential Water Heater Warranty — Limited Lifetime
Commercial Water Heater Warranty — Limited 15 Year
First Year — (Residential and Commercial Water Heaters) Weil-McLain warrants
that its indirect-fired water heaters are free from defects in material and workmanship
for one year from the date of installation. If any parts are found to be defective from
such defects, Weil-McLain will provide replacement of such defective parts.
Second Year and Beyond — (Residential Only)
Second Through Fifth Years — (Commercial Only)
Weil-McLain warrants that the tank assembly components of its indirect-fired water
heaters are free from defects in material and workmanship for the second through
the fifth year from the date of installation (commercial only), or for the second year
from the date of installation and beyond (for residential only). If, during such time
periods, a leak in the tank assembly should occur, Weil-McLain will provide replace-
ment for the original tank assembly.
Sixth Year through Fifteenth Year — (Commercial Only) Weil-McLain warrants
that the tank assembly components of its commercial indirect-fired water heaters are
free from defects in material and workmanship for the sixth year through the fifteenth
year following the date of installation. If, during such time period, a leak in the tank
assembly should occur, Weil-McLain will provide replacement for such defective tank
assembly. Such replacement will be furnished with the nearest comparable model
available from Weil-McLain at the time of such replacement and upon payment of a
proportionate charge. Proportionate charges will be equal to the appropriate percent-
age of the current list price of such commercial indirect-fired water heater at the time
warranty claim is made and will be determined as follows: 6th & 7th year-55%; 8th &
9th year-60%; 10th & 11th year-65%; 12th & 13th year-70%; 14th & 15th year-75%.
These warranties do not cover:
1. Any water heater not initially installed with a new temperature-pressure relief valve
bearing the listing of the American Society of Mechanical Engineers (A.S.M.E.) at the
time of the water heater installation.
2. Any water heater that has a failure or malfunction resulting from a.) failure to keep the
tank full of potable water; b.) failure to assure that water in the tank is free to circulate
at all times; or c.) failure to keep the tank free of water sediment or scale deposits.
3. Any water heater that has potable water in the unit with a chloride or chlorine content
higher than 80 mg/liter.
4. Any water heater installed in a residence containing any type of water softener system
that is not installed and maintained in accordance with manufacturer’s specifications.
5. Any water heater installation where non-metallic piping products without an oxygen
barrier are used.
6. Any water heater used for non-potable application such as pool or process heating.
See section “For all Weil-McLain Products” for additional warranty information.
Weil-McLain
Ultra
Cast Aluminum Boilers
Residential Warranty — Limited 15 Year
(includes 5-Year Ultra Protection Plan)
Commercial Warranty — Limited 15 Year
(does NOT include Ultra HPP)
First Through Fifth Year — Weil-McLain warrants that its cast aluminum boilers
are free from defects in material and workmanship for one year from the date of
installation and the heat exchanger is free from defects in material and
workmanship for five years from the date of installation. If any parts in the first
year, or the heat exchanger in the first five years are found to be defective from
such defects, Weil-McLain will provide replacement of such defective parts or heat
exchanger.
In addition to the product warranty, Weil-McLain will provide a 5-Year “
Ultra”
Homeowner Protection Plan (“UHPP”) for residential applications only to cover parts and labor
for five years from the date of installation provided only if the Ultra boiler is properly registered
with the UHPP Administrator within one month of the date of installation. UHPP claims must be
processed directly through the Plan Administrator and not through Weil-McLain.
Sixth Through Tenth Year — Weil-McLain warrants that the heat exchangers of
its cast aluminum boilers are free from defects in material and workmanship for
the sixth through the tenth year from the date of installation. If, during such time,
the heat exchanger is found to be defective, Weil-McLain will provide replacement
of such defective heat exchanger.
Eleventh Through Fifteenth Year — Weil-McLain warrants that the heat
exchangers of its cast aluminum boilers are free from defects in material and
workmanship for the eleventh through fifteenth year from the date of installation.
If, during such time period, the heat exchanger is found to be defective, Weil-
McLain will provide replacement for such defective heat exchanger upon the
payment of a proportionate charge based on the time the boiler has been in
service. The proportionate charge will be equal to the appropriate percentage of
the list price of such heat exchanger at the time the warranty claim is made, and
will be determined as follows: 11th year - 10%; 12th year - 20%; 13th year -
40%; 14th year - 60%; 15th year - 80%; 16th year & beyond - 100%.
This warranty does not cover boilers operated with combustion air contaminated
externally by chemical vapors or with improper fuel additives, or with water/
system conditions which may have caused heat exchanger failure.
See section “For all Weil-McLain Products” for additional warranty information.
Radiant Heating Products
Radiant Heating Products Warranty — Limited 30 Year
IPP & IPC Products Warranty — Limited 3 Year
Weil-McLain warrants that its AlumiPex and Qual-Pex radiant heating products are
free from defects in material and workmanship for thirty years (three years for IPP
and IPC products) from the date of installation. If any parts are found to be defective
from such defects during such time period, Weil-McLain will provide replacement of
such defective parts. It is expressly understood that failure as a result of freezing of
water within the pipes (tubing) does not constitute a defect in material or
workmanship and shall not be covered by this warranty.
See section “For all Weil-McLain Products” for additional warranty information.
Parts and Accessories
Parts and Accessories Warranty — Limited 1 Year
Weil-McLain warrants that parts and accessories that were purchased through Weil-
McLain are free from defects in material and workmanship for one year from the date
of installation. If any parts and/or accessories are found to be defective from such
defects during such time period, Weil-McLain will provide replacement of such
defective parts. Parts and accessories covered under this warranty include only
those items that are not covered under other Weil-McLain product warranties.
See section “For all Weil-McLain Products” for additional warranty information.
For All Weil-McLain Products: These warranties are subject to the condition
that the Weil-McLain Product(s) must have been installed in accordance with
manufacturers’ instructions by a heating contractor whose principal occupation is
the sale and installation of plumbing, heating and/or air conditioning equipment.
These warranties extend only to the first retail purchaser of the products and only
to a product that has not been moved from its original installation site.
In addition to each product warranty listed, Weil-McLain warranties do not cover:
1. Components that are part of the heating system (products) but were not fur-
nished by Weil-McLain as a part of the heating system (products).
2. The workmanship of any installer of Weil-McLain’s product(s). In addition, this
warranty does not assume any liability of any nature for unsatisfactory perform-
ance caused by improper installation.
3. Any costs for labor for removal and reinstallation of the alleged defective part,
transportation to Weil-McLain, if necessary, and any other materials necessary
to perform the exchange.
4. Any products that have a failure or malfunction resulting from improper or
negligent operation, accident, abuse, freezing, misuse, unauthorized alteration
or improper repair or maintenance.
5. Improper adjustments (including boiler/burner), control settings, care or mainte-
nance. Information is in the installation, start-up, operations, owner/user’s
manuals, service/maintenance instructions, and other printed/technical informa-
tion provided with the product or direct from Weil-McLain or weil-mclain.com.
April 1, 2003
Part No. 550-141-950/0403
