Weil-McLain 80 - Manuals

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Manual

Manual Weil-McLain 80

Summary

Page 2 - Hazard Definitions; Contents; Page

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 2 Part No. 550-141-935/0602 Hazard Definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of variousrisk levels, or to important information concerning the life of the...

Page 3 - • Installation • Start-Up • Maintenance • Parts; Installation must comply with —; Before selecting boiler location; Before installing boiler; Provide clearance around boiler; Figure 1; Boiler foundation; Table 1

• Installation • Start-Up • Maintenance • Parts 3 Part No. 550-141-935/0602 Installation must comply with — • State, prov incial and local plumbing, heating andelectrical codes. • Regulations of servicing utilities. • National codes where applicable. Before selecting boiler location 1. Check for nea...

Page 4 - Figure 2; Figure 3; C o m b u s t i o n a n d v e n t i l a t i o n a i r

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 4 Part No. 550-141-935/0602 Before installing boiler (continued) 1 Figure 2 C o m b u s t i o n a n d v e n t i l a t i o n a i r openings — Boiler room below grade Figure 3 C o m b u s t i o n a n d v e n t i l a t i o n a i r op...

Page 5 - Set boiler in place; Table 2; Lifting weights

• Installation • Start-Up • Maintenance • Parts 5 Part No. 550-141-935/0602 Set boiler in place 2 For packaged boiler: 1. Remove top jacket panels. Set aside until after boiler is piped. The boiler contains ceramic fiber andf i b er g l a s s m a t er i a l s . Us e c a re w h enhandling these mater...

Page 6 - Assemble block; Install back refractory blanket; Figure 4; Figure 5

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 6 Part No. 550-141-935/0602 Assemble block 3 Sections are top heavy. Unbolted sectionsmay fall if not supported, resulting insevere personal injury or death. Install back refractory blanket 1. Lay back section on floor with ports ...

Page 7 - Install intermediate sections; Leave an equal amount of thread on each end; Figure 6; Table 3; Prepare remaining sections

• Installation • Start-Up • Maintenance • Parts 7 Part No. 550-141-935/0602 Install intermediate sections Sections are top heavy. Unbolted sections may fall if notsupported, resulting in severe personal injury or death. 1. Remove and discard 3 / 8 " diameter shipping tie rods. 2. Remove grit fro...

Page 8 - Perform hydrostatic pressure test; Prepare boiler and test:; Steam

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 8 Part No. 550-141-935/0602 Perform hydrostatic pressure test Prepare boiler and test: 1. See pages 28 and 29 for tapping locations. Install: a. Boiler drain (not furnished).b. Water pressure gauge — for test only. Be sure gauge c...

Page 9 - Install burner mounting plate on front section; Install observation port assemblies on front and back sections:; Install cleanout plates; Complete block assembly; Figure 7

• Installation • Start-Up • Maintenance • Parts 9 Part No. 550-141-935/0602 Install burner mounting plate on front section 1. Install four ½" x 4¾" studs to secure burner mounting plate to section: a. Thread and lock together two nuts on rounded end of stud. Thread flat end of stud into one ...

Page 10 - Install flue collector; Figure 8; Figure 9; Flue collector assembly

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 10 Part No. 550-141-935/0602 Install flue collector 6 Figure 8 Collector hood preparation Figure 9 Flue collector sealing rope installation Flue collector assembly 1. Figure 10, page 11, shows flue collector components and locatio...

Page 12 - Before installing flue collector

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 12 Part No. 550-141-935/0602 Install flue collector (continued) 6 Before installing flue collector 1. See Figure 10, page 11, for general assembly of flue collector components. 2. See Figure 11, page 13 for the placement of flue c...

Page 14 - Connect water boiler piping; General water piping information:; Table 7; ASME drain valve size; Table 6; Recommended minimum pipe sizes for; Table 5; Recommended minimum pipe sizes when flow rate is

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 14 Part No. 550-141-935/0602 Connect water boiler piping 7 General water piping information: • System water supply and return piping should be installed and pipingconnections attached to boiler before erecting jacket or installing...

Page 15 - Multiple water boiler piping; Gross output

• Installation • Start-Up • Maintenance • Parts 15 Part No. 550-141-935/0602 Connect water boiler piping (continued) 7 3. Piping for multiple boilers (see Figure 13): A S i ze s e con d a r y b o i l er p u m p G P M b a s e d o nfollowing formulas: Calculate only secondary piping circuit resistance...

Page 16 - Connect steam boiler piping; General steam piping information:; Cold water fill piping; Table 8; Steam boiler pipe size for typical 2-pipe steam systems

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 16 Part No. 550-141-935/0602 Connect steam boiler piping 8 General steam piping information: • Hartford loop piping arrangement and wet return arerequired for steam boilers. Use the Hartford loop forboth pumped-return and gravity-...

Page 17 - Model 380 through 580 steam boiler piping — NOTE

• Installation • Start-Up • Maintenance • Parts 17 Part No. 550-141-935/0602 Connect steam boiler piping (continued) 8 Figure 15 Model 380 through 580 steam boiler piping — NOTE minimum 24 inches between boiler water line and bottom of header. Figure 16 Model 680 through 980 steam boiler piping — NO...

Page 18 - Table 9; Condensate receiver capacity

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 18 Part No. 550-141-935/0602 Table 9 Condensate receiver capacity Figure 18 Condensate piping to boiler Connect steam boiler piping (continued) 8 Figure 17 Model 1080 through 1280 steam boiler piping — NOTE minimum 24 inches betwe...

Page 20 - Install jacket; Before installing jacket; Install jacket front and rear panels

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 20 Part No. 550-141-935/0602 Install jacket 9 Before installing jacket 1. Packaged boilers • Install top jacket panels per instructions in thismanual. 2. Non-packaged boilers • Follow the instructions in this section to install al...

Page 22 - Install jacket side panels

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 22 Part No. 550-141-935/0602 Figure 21 Installing (removing) jacket side panels and top panels Install jacket (continued) 9 Install jacket side panels 1. Remove jacket side panels from cartons. 2. Insert a plastic plug (provided i...

Page 27 - To pipe tankless heaters:; Pipe tankless heaters

• Installation • Start-Up • Maintenance • Parts 27 Part No. 550-141-935/0602 To pipe tankless heaters: 1. Size piping no smaller than heater inlet and outlet.2. Automatic mixing valve must be installed. See Figure 26. Follow manufacturer’s instructions to install. 3. Flow regulating valve must be in...

Page 28 - Install water boiler controls

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 28 Part No. 550-141-935/0602 Install water boiler controls Install controls: 1. Install furnished controls where shown in Table 11 and Figure 27. Failure to properly install, pipe and wireboiler controls can result in severe damag...

Page 29 - Install steam boiler controls

• Installation • Start-Up • Maintenance • Parts 29 Part No. 550-141-935/0602 Install steam boiler controls 12 Install controls: 1. Install controls where shown in Table 12 and Figure 28. Failure to properly install, pipe and wireboiler controls can result in severe damageto boiler, building and pers...

Page 31 - Connect breeching and venting systems; General venting information; Forced draft; Construct metal breeching:

• Installation • Start-Up • Maintenance • Parts 31 Part No. 550-141-935/0602 13 Connect breeching and venting systems Figure 31 Stub vent – forced draft — single boiler Figure 33 Conventional chimney – balanced draft with barometric draft control when required — single boiler Figure 32 Stub vent – f...

Page 32 - To wire burner and boiler controls:

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 32 Part No. 550-141-935/0602 Install burner 14 Wiring and fuel piping Make final adjustments 16 15 To install burner: 1. Unpack burner.2. Place gasket around air tube and against burner mounting flange. If sealing rope is used, ap...

Page 33 - Make final adjustments

• Installation • Start-Up • Maintenance • Parts 33 Part No. 550-141-935/0602 Make final adjustments (continued) 16 Figure 35 Flue damper assembly, typical Skim steam boilers: Clean all newly installed steam boilers toremove oil. Failure to properly clean canresult in violent water level fluctuations...

Page 34 - Dimensions and ratings; Notes

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 34 Part No. 550-141-935/0602 Dimensions and ratings 17 Notes 1. Burner input based on maximum of 2,000 feet altitude. For higher altitudes consult local Weil-McLain representative. 2. No. 2 fuel oil Commercial Standard Spec. CS75-...

Page 36 - Parts

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 36 Part No. 550-141-935/0602 18 Parts

Page 38 - Handling ceramic fiber and fiberglass materials; REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS; NIOSH stated First Aid.; REMOVAL OF FIBERGLASS WOOL — OR —; NIOSH stated First Aid.; Eye: Irrigate immediately

Weil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fired Burners 38 Part No. 550-141-935/0602 Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materia...

Page 39 - Propane boilers — propane gas odorant; Periodically check the odorant level of your gas.

• Installation • Start-Up • Maintenance • Parts 39 Part No. 550-141-935/0602 Propane boilers — propane gas odorant Propane boilers only — Your propane supplier mixes an odorant with the propane to make itspresence detectable. In some instances, the odorant can fade and the gas may no longer havean o...