Instruction/ maintenance manual of the product 80 Weil-McLain
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P art N o. 550-141-935/0602 Boiler Manual 80 W ater & steam boilers for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners This manual must only be used by a qualified heat ing installer/serv ice technician. R ead all inst ructions before installing.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 2 P art No . 550-141-935/0602 Hazar d Definitions The following defined terms are used thr oughout this manual to bring attention t o the presenc e of hazards of various risk levels, or to important information conc erning the life of the product.
• Installation • Start-Up • Maintenance • Parts 3 P art No . 550-141-935/0602 Installation must compl y with — • State, pr ov incial and local plumbing, heating and electr ical codes. • R egulations of serv icing utilities. • N ational codes where applicable.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 4 P art No . 550-141-935/0602 Befor e installing boiler (continued) 1 Figure 2 Combustion and v entilation air openings — Boil.
• Installation • Start-Up • Maintenance • Parts 5 P art No . 550-141-935/0602 Set boiler in place 2 For packa ged boiler: 1. Remo ve top jack et panels. Set aside until after boiler is piped. The boiler contains ceramic fiber and fiberglass materials.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 6 P art No . 550-141-935/0602 Assemble block 3 Sections are top heavy . U nbolted sections ma y fall if not supported, r esulting in seve re personal inj ury or death. Install bac k refractory blanket 1.
• Installation • Start-Up • Maintenance • Parts 7 P art No . 550-141-935/0602 Install intermediate sections Sections are top hea vy . U nbolted sections may fall if not supported, resulting in se ve re personal injury or death. 1. R emove and discar d 3 / 8 " diameter shipping tie r ods.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 8 P art No . 550-141-935/0602 Perform hydr ostatic pr essur e test Prepare boiler and test: 1. See pages 28 and 29 for tapping locations. I nstall: a. Boiler drain (not furnished).
• Installation • Start-Up • Maintenance • Parts 9 P art No . 550-141-935/0602 Install burner mounting plate on fr ont section 1. Install four ½" x 4¾" studs to secure burner mounting plate to section: a. Thread and lock together two nuts on r ounded end of stud.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 10 P art No . 550-141-935/0602 Install flue collector 6 Figure 8 Collector hood preparation Figure 9 Flue collector sealing rope installation Flue collector assembl y 1. Figure 10, pag e 11, shows fl ue collector compo nents and locations.
• Installation • Start-Up • Maintenance • Parts 11 P art No . 550-141-935/0602 Install flue collector (continued) 6 Figure 10 Flue collector components, typical (Model 880 collector configurat.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 12 P art 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 c omponents.
• Installation • Start-Up • Maintenance • Parts 13 P art No . 550-141-935/0602 Figure 11 Flue collector components by model (see Figure 10, page 11 f or flue collector components not shown bel.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 14 P art No . 550-141-935/0602 Connect water boiler piping 7 General water piping information: • Syst em wat er supply and r eturn piping should b e installed and piping connections attach ed to boiler befor e erecting jacket or installing co ntrols.
• Installation • Start-Up • Maintenance • Parts 15 P art No . 550-141-935/0602 Connect water boiler piping (continued) 7 3. Piping for multiple boilers (see Figure 13): A Size seco ndar y boiler pump GPM based on following form ulas: Calculat e only secondary piping circuit resistanc e.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 16 P art No . 550-141-935/0602 Connect steam boiler piping 8 General steam piping information: • Hartfor d loop piping arrangement and wet return are required fo r steam boile rs.
• Installation • Start-Up • Maintenance • Parts 17 P art No . 550-141-935/0602 Connect steam boiler piping (continued) 8 Figure 15 Model 380 through 580 steam boiler piping — NO TE minimum 24 inches betw een boiler water line and bottom of header .
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 18 P art No . 550-141-935/0602 T able 9 Condensate receiv er capacity Figure 18 Condensate piping to boiler Connect steam boiler.
• Installation • Start-Up • Maintenance • Parts 19 P art No . 550-141-935/0602 Figure 19 Multiple Steam Boiler Piping Gravity Condensate Return Connect steam boiler piping (continued) 8 A Pipe as shown for gr avity return systems, c onnecting point A t o the wet gravity return.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 20 P art No . 550-141-935/0602 Install jacket 9 Before installing jac ket 1. P ackaged boile rs • Install top jack et panels per instruc tions in this manual. 2. N on-packaged boilers • Follow the instructions in this section to install all jacket panels.
• Installation • Start-Up • Maintenance • Parts 21 P art No . 550-141-935/0602 Figure 20 Installing jack et suppor t brack ets and rails and jac ket front and rear panels Install jacket (conti.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 22 P art No . 550-141-935/0602 Figure 21 Installing (removing) jack et side panels and top panels Install jacket (continued) 9 Install jacket side panels 1. Re move jack et side panels from cartons.
• Installation • Start-Up • Maintenance • Parts 23 P art No . 550-141-935/0602 Figure 22 Jac ket side panel placement — Models 380, 480, 580 and 680 Install jacket (continued) 9.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 24 P art No . 550-141-935/0602 Figure 23 Jac ket side panel placement — Models 780, 880 and 980 Install jacket (continued) 9.
• Installation • Start-Up • Maintenance • Parts 25 P art No . 550-141-935/0602 Figure 24 Jac k et side panel placement — Models 1080, 1180, and 1280 Install jacket (continued) 9.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 26 P art No . 550-141-935/0602 Figure 25 J ack et top panel placement Install jacket (continued) 9.
• Installation • Start-Up • Maintenance • Parts 27 P art No . 550-141-935/0602 T o pipe tankless heaters: 1. Size piping no smaller than heater inlet and outlet. 2. A uto matic mixing valve must be installed. See Figure 26. Follow manufact urer’ s instr uctions to install.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 28 P art No . 550-141-935/0602 Install water boiler controls Install controls: 1.
• Installation • Start-Up • Maintenance • Parts 29 P art No . 550-141-935/0602 Install steam boiler controls 12 Install controls: 1. Install controls whe re shown in T able 12 and Figure 28.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 30 P art No . 550-141-935/0602 Install steam boiler contr ols (continued) 12 Figure 29 Steam control siphon and fittings T able .
• Installation • Start-Up • Maintenance • Parts 31 P art No . 550-141-935/0602 13 Connect br eeching and venting systems Figure 31 Stub vent – f orced draft — single boiler Figure 33 Conv .
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 32 P art No . 550-141-935/0602 Install bur ner 14 Wiring and fuel piping Make final adjustments 16 15 T o install burner: 1. U npack b urner . 2. Place gasket around air tube and against burner mounting flange.
• Installation • Start-Up • Maintenance • Parts 33 P art 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 to remov e oil.
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 34 P art 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.
• Installation • Start-Up • Maintenance • Parts 35 P art No . 550-141-935/0602 17 Dimensions and ratings (continued).
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 36 P art No . 550-141-935/0602 18 Parts.
• Installation • Start-Up • Maintenance • Parts 37 P art No . 550-141-935/0602 18 Parts (continued).
W eil-McLain 80 Boiler For Gas, Light Oil, Gas/Light Oil Fir ed Burners 38 P art No . 550-141-935/0602 Handling ceramic fiber and fiberglass materials REMO V AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The combustion chambe r lining or base insulation panels in this product contain c eramic fiber materials.
• Installation • Start-Up • Maintenance • Parts 39 P art No . 550-141-935/0602 P ropane boilers — propane gas odorant Pr opane boilers o nly — Y our pr opane supplier mix es an odorant w ith the pro pane to make its prese nce detectable. In some instances, the odor ant can fade and the gas may no longer ha ve an odor .
W eil-McLain Limited W arranty f or Residential & Commercial Cast Iron Boilers ◆ ◆ ◆ ◆ ◆ RESIDENTIAL W A TER W ARRANTY—Limited Lifetime ◆ ◆ ◆ ◆ ◆ RESIDENTIAL STEAM W ARRANTY.
An important point after buying a device Weil-McLain 80 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Weil-McLain 80 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Weil-McLain 80 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Weil-McLain 80 you will learn all the available features of the product, as well as information on its operation. The information that you get Weil-McLain 80 will certainly help you make a decision on the purchase.
If you already are a holder of Weil-McLain 80, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Weil-McLain 80.
However, one of the most important roles played by the user manual is to help in solving problems with Weil-McLain 80. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Weil-McLain 80 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
