Weil McLain 88 User Manual
88  
Water & steam boilers – Series 2  
for use with Gas, Light Oil, & Gas/Light Oil – Fired Burners  
• Maintenance  
• Parts  
• Installation  
• Startup  
Boiler Manual  
For additional  
information, refer to . .  
Burner  
specification and  
data sheets  
for burners pre-tested  
with model 88 boilers  
This manual must only be used by a qualified INSTALLER Consider piping and installation when determining  
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.  
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.  
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.  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Contents  
Before installing boiler                                           4  
Set boiler in place                                                 7  
Assembling the block                                             8  
Perform hydrostatic pressure test                              11  
Complete block assembly                                       12  
Connect water boiler piping                                    14  
Connect steam boiler piping                                    16  
Install jacket                                                      20  
Pipe tankless heaters                                            25  
Install water boiler controls                                     26  
Install steam boiler controls                                    27  
Connect breeching and venting systems                      29  
Install burner & wiring and fill system                          31  
Install fuel piping                                                32  
Make final adjustments                                          33  
Handling ceramic fiber and fiberglass materials              34  
Ratings                                                            35  
Dimensions                                                      36  
Parts                                                              38  
Warranty                                                          40  
Part No. 550-100-068/0308  
3
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Before installing boiler  
Installation must comply with —  
Figure 1 Boiler foundation, when required  
1. State, provincial and local plumbing, heating and electrical  
codes.  
2. Regulations of servicing utilities.  
3. ASME Section IV, Low Pressure Boiler and Pressure Vessel Code.  
4. National Fuel Gas Code, ANSI/NFPA 54, when applicable.  
5. National codes where applicable.  
Before selecting boiler location  
1. Check for nearby connections to:  
a. Fuel supply.  
b. Electrical power.  
c. System water or steam piping.  
d. Venting systems - see page 29.  
e. Combustion and ventilation air supply — see page 5.  
2. Check area around boiler. Remove any combustible materials,  
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.  
Figure 2 Boiler foundation (see Figure 1)  
Boiler model  
Length, L, minimum  
Provide clearance around boiler  
number  
(inches)  
1. Provide minimum clearances to combustible materials:  
•
•
•
•
•
•
•
Boiler top — 24 inches.  
Boiler front — 48 inches.  
Boiler flue — 9 inches.  
Boiler rear — 9 inches.  
488  
588  
33  
41  
688  
49  
Boiler sides — 6 inches.  
788  
57  
Single-wall vent pipe – 18 inches.  
Double-wall vent pipe – refer to vent pipe manufacturer's  
recommendations for vent pipe clearances.  
888  
65  
2. Boiler may be installed on combustible ooring.  
3. See page 36 for boiler dimensions.  
988  
73  
1088  
1188  
1288  
1388  
1488  
1588  
1688  
1788  
1888  
81  
Flue pipe/breeching clearances take precedence over  
jacket clearances.  
89  
97  
4. Provide minimum clearances for servicing:  
•
Left side — for cleaning and tankless heater removal –  
39 inches.  
105  
113  
121  
129  
137  
145  
•
•
Rear — 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  
1. Floor construction and condition must be suitable for weight of  
boiler when filled with water. See page 36 for approximate boiler  
operating weight.  
2. A level concrete or brick foundation, constructed per Figure 1 and  
Figure 2 is required when:  
a. A oor could possibly become ooded.  
b. Non-level conditions exist.  
4
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
(continued)  
Before installing boiler  
Combustion and ventilation air openings  
Figure 3 Combustion and ventilation air openings  
— Boiler room below grade  
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.  
Figure 4 Combustion and ventilation air openings  
— Boiler room partially or completely  
above grade  
Combustion air openings to inside  
Required volume of interior spaces  
ANSI/NFPA 54 allows combustion air to be supplied through openings  
to interior spaces if the volume of the connected interior spaces  
meets the minimum volume required by the standard.  
The minimum volume of interior spaces can be taken as 50 cubic feet  
per 1,000 Btuh of all appliances in the spaces, or the minimum volume  
can be calculated using the formulas given in ANSI/NFPA 54. Excep-  
tion: If the air infiltration rate for the spaces is known to be less than  
0.40 air changes per hour, the minimum volume must be calculated  
as specified in the standard.  
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:  
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).  
Combining spaces on the same story — Each opening shall have  
a minimum free area of 1 in2/1000 Btuh (2200 mm2/kW) of the total  
input rating of all appliances in the space but not less than 100 in2  
(0.06 m2). One opening shall commence within 12 inches (300 mm)  
of the top, and one opening shall commence within 12 inches (300  
mm) of the bottom, of the enclosure. The minimum dimension of air  
openings shall be not less than 3 inches (80 mm).  
Outside openings: TWO permanent openings  
method  
Combining spaces in different stories — The volumes of spaces  
in different stories shall be considered as communicating spaces where  
such spaces are connected by one or more openings in doors or oors  
having a total minimum free area of 2 in2/1000 Btuh (4400 mm2/kW)  
of total input rating of all appliances.  
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  
Part No. 550-100-068/0308  
5
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
(continued)  
Before installing boiler  
freely communicate with the outdoors, as follows:  
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 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 exhaust fans are installed in the building,  
additional air shall be provided to replace the  
exhausted air.  
•
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.  
•
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.  
Outside openings: ONE permanent opening method  
•
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.  
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:  
Louvers, Grilles, and Screens.  
The required size of openings for combustion, venti-  
lation, and dilution air shall be based on the net free  
area of each opening.  
(1) 1 in2/3000 Btu/hr (700 mm2 per kW) of the total input rating of  
all appliances located in the enclosure, and . . .  
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.  
(2) Not less than the sum of the areas of all vent connectors in the  
space.  
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.  
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.  
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.  
Engineered Installations  
Motorized louvers  
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.  
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.  
Mechanical Combustion Air Supply  
Where all combustion air is provided by a mechanical air supply  
6
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Set boiler in place  
Ensure the equipment and cables used for lifting are  
Figure 5 Section assembly lifting weights  
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.  
Boiler  
model  
Approximate  
lifting  
Minimum  
sling length —  
number  
weight  
(from crane hook to  
boiler lifting lugs)  
(pounds)  
For packaged boiler:  
1. Remove top jacket panels. Set aside until after boiler is piped.  
488  
588  
2928  
3490  
4152  
4714  
5276  
5838  
6400  
7062  
7624  
8186  
8748  
9310  
9872  
10,584  
11,146  
2' 6"  
3' 0"  
4' 0"  
4' 6"  
5' 0"  
6' 0"  
6' 6"  
7' 0"  
8' 0"  
8' 6"  
9' 0"  
10' 0"  
10' 6"  
11' 0"  
12' 0"  
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.  
688  
788  
888  
2. Remove lag screws (2 in front, 2 in rear) from shipping rails.  
988  
3. Remove boiler from skid. Cables are already attached to block as-  
sembly. See Figure 5 for lifting weight.  
1088  
1188  
1288  
1388  
1488  
1588  
1688  
1788  
1888  
•
•
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.  
4. Place boiler in final position. Center boiler on foundation, if  
used.  
5. Level boiler. Shim under skid angles, if necessary.  
6. Cut off cables.  
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.  
7. Proceed to "Perform hydrostatic pressure test," page 11.  
For block assembly:  
1. Remove lag screws (2 in front, 2 in rear) from shipping rails.  
Gas tight seal must be maintained to pre-  
vent possible ue gas leakage and carbon  
monoxide emissions, resulting in severe  
personal injury or death.  
2. Remove boiler from skid. Cables are already attached to block as-  
sembly. See Figure 5 for lifting weight.  
a. Check inside section assembly for any light  
passing through unsealed areas.  
b. Mark all unsealed areas.  
•
•
Using crane – attach free end of cables to eye of crane.  
Using hoist – attach free end of cables to hoist. Raise boiler off skid.  
Use pipe rollers under steel skid angles to roll boiler.  
c. At unsealed areas, check for:  
3. Place boiler in final position. Center boiler on foundation, if  
used.  
•
•
•
Damaged gaskets.  
4. Level boiler. Shim under skid angles, if necessary.  
5. Cut off cables.  
Sealing rope not in place.  
Loose bolts or nuts.  
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.  
d. Correct all conditions and repeat step b. If un-  
sealed areas still exist,contact yourWeil-McLain  
distributor or sales office before continuing  
installation.  
6. Inspect block assembly for disjointed sections. Check gas-tight seal  
of ue collector hood and cleanout plates.  
7. Proceed to "Perform hydrostatic pressure test,"  
page 11.  
Part No. 550-100-068/0308  
7
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Assembling the block  
Figure 6 Sealing rope installation  
Sections are top heavy. Unbolted sections may fall  
if not supported, resulting in severe personal injury  
or death.  
Prepare and position back section  
1. Apply 1/8" continuous bead of sealing rope adhesive in sealing rope  
grooves. See Figure 6. Do not get any adhesive on machined  
port surfaces.  
2. Place ½" sealing rope in groove.Around curves,grasp at 1" intervals  
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.  
3. Remove any grit from port machined surfaces with clean rag.  
Do not use petroleum-based cleaning or sealing com-  
pounds in boiler system. Severe damage to system  
components can result, causing substantial property  
damage.  
4. Place 9" and 6" sealing rings in appropriate port openings. See  
Figure 6. If sealing ring slips out of groove, stretch ring gently for  
several seconds, then reposition in groove.  
1
5. Apply continuous bead of silicone sealant no larger than /16"  
Figure 7 Silicone sealant  
around entire outside edge of outer machined surface of port.  
Refer to Figure 7. Do not apply silicone sealant on, next to or  
under sealing ring.  
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.  
6. Hoist back section upright. Then temporarily screw a 6-inch  
threaded pipe at least 36 inches long into the lower (return) tap-  
ping.  
7. Hoist the section and put into position.  
8. Place a block under the 6-inch pipe to hold the back section up-  
right and plumb.  
The back section must be plumb before installing other  
sections to ensure the block will assemble correctly.  
9. The 6-inch support pipe and block can be removed after several  
sections have been installed, and the assembly is stable.  
10. Install intermediate sections as described on the following page.  
8
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Assembling the block  
Figure 8 Sealing ring installation and port  
Sections are top heavy. Unbolted sections may fall  
if not supported, resulting in severe personal injury  
or death.  
alignment  
Install intermediate sections  
1. Remove and discard 3/8" diameter shipping tie rods.  
2. Remove grit from port machined surfaces with clean rag.  
Do not use petroleum-based cleaning or sealing com-  
pounds in boiler system. Severe damage to system  
components can result, causing substantial property  
damage.  
3. Position intermediate section so aligning lugs fit into sockets of  
next section. See Figure 8.  
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.  
4. Install TI (tankless intermediate) and SI (supply intermediate)  
sections (when used) in order shown in Figure 9, page 10.  
5. Draw sections together until metal-to-metal contact is made  
around machined port openings (see Figure 8):  
6. Repeat steps 1-5.  
a. Oil threads on 4 draw rods. Install washer and nut on end to  
be tightened. Use nut only on other end.  
7. Check each section for proper sealing rope position  
before proceeding to next section.  
b. Uniformly draw sections together, starting at washer/nut  
end.  
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.  
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.  
c. Draw rods should be torqued to a range of 90 to 100 ft-lbs. Do  
not back off draw rods.  
8. Install remaining intermediate sections and front  
section using the same procedure.  
d. Metal-to-metal contact will be achieved around port openings.  
See Figure 8. If gap occurs, it should be no greater than .032".  
Check with feeler gauge.  
If using tankless heater (TI)  
sections  
e. If, for any reason, gap around machined port opening exceeds  
.032", check for rope extending from rope grooves, dirt on port  
openings or sockets, or misaligned lugs. If corrections are made  
and gap still exists, contact your Weil-McLain distributor or  
sales office before continuing installation.  
•
Install tankless heaters and gaskets or heater cover  
plates and gaskets. Use /8" x /4" studs, washers  
3
3
and nuts.  
Part No. 550-100-068/0308  
9
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
(continued)  
Assembling the block  
Figure 9 Section arrangement  
Max  
number  
of  
tankless  
heaters  
Boiler model  
number  
Section arrangement  
(all heaters must be on left side of boiler)  
W = water  
S = steam  
F = front / B = back / I = Intermediate  
TI = tankless intermediate SI = supply intermediate (steam only)  
"I" can be substituted for "TI" sections  
1
2
2
3
3
4
4
5
5
4
6
6
6
5
7
7
7
7
8
8
8
6
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀB  
488 W&S  
588 W&S  
688 W&S  
788 W&S  
888 W&S  
988 W&S  
1088 W&S  
1188 W&S  
1288 W  
1288 S  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀSIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀSIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀSIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀSIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀB  
Fꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀTIꢀ•ꢀIꢀ•ꢀB  
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1388 W  
1388 S  
1488 W  
1488 S  
1588 W  
1588 S  
1688 W  
1688 S  
1788 W  
1788 S  
1888 W  
1888 S  
10  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Perform hydrostatic pressure test  
Prepare boiler and test:  
Figure 11 Boiler tappings  
1. See Figure 10 and Figure 11 for tapping locations. Install:  
a. Boiler drain (not furnished).  
b. Water pressure gauge — for test only. Be sure gauge can handle  
test pressure — see step 3.  
c. Air vent in upper tapping (K).  
2. Plug remaining tappings.  
Do not pressure test with any control installed. Damage  
to control can occur due to overpressure.  
3. Fill boiler.Vent all air. Pressure test at least 10 minutes at a pressure  
not less than the following:  
a. Steam boiler: Between 45 and 55 psig.  
b. Water boiler: 1½ times maximum allowable working  
pressure (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.  
4. Check for maintained gauge pressure and leaks. Repair if found.  
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.  
5. Drain boiler and remove air vent, boiler drain and gauge. Remove  
plugs from tappings that will be used for controls and accesso-  
ries.  
Figure 10 Boiler tapping locations and sizes (see Figure 11)  
Location  
Size  
Steam  
Water  
A
2"  
Steam relief valve and/or  
Skim tapping  
High limit  
Manual reset limit  
B
L
2"  
1"  
1"  
Steam relief valve  
Secondary probe LWCO  
Low water cut-offs  
—
Water relief valve  
Not used — Plug  
C1 & C2  
C1  
Alternate low water cut-offs  
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  
F1 & F2  
G
½"  
C\,"  
¾"  
Gauge glass  
—
—
Try cock tappings  
Pressure limit control,  
Pressure operating control and  
pressure gauge,  
Combination pressure–  
temperature gauge  
Firing rate pressure control  
(when used)  
H
K
¾"  
1"  
Boiler drain (see Figure 17,  
page page 15, for system blow-  
off (drain) valve locations and  
sizes  
Boiler drain  
—
Piping to compression tank or  
automatic air vent  
Part No. 550-100-068/0308  
11  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Complete block assembly  
b. Position 3/8" sealing rope in groove.  
Install burner mounting plate on front  
section  
c. Secure assembly to section. Use 10-32 x ¾"  
truss-head screws.  
1. Install four ½" x 3½" studs to secure burner mounting plate to  
section:  
2. Repeat above steps for back observation port as-  
sembly.  
a. Thread and lock together two nuts on rounded end of stud.  
Thread at end of stud into one of four holes located around  
opening.  
b. Remove nuts.  
c. Repeat steps a and b for remaining studs.  
Insert HXT-bars  
1. See Figure 12, page 12.  
2. Flue HXT-bars are identified by painted ends. They  
must be inserted as shown, with the HXT-bars in  
the sequence:  
2. Install burner mounting plate:  
a. Apply 1/8" continuous bead of sealing rope adhesive in groove  
around opening in section.  
•
Top position  
red-tipped, HXT-bar 24 inches long —  
place on the top row of pins.  
Middle position  
b. Position ½" sealing rope in groove. Overlap ends at least one  
inch.  
c. Install burner mounting plate with part number and the word,  
"UP," positioned at top. Use ½" washers and nuts.  
•
•
•
white-tipped HXT-bar, 26 inches long —  
place on the first row of pins below the top  
clean-out plate boss.  
Install observation port assemblies on front  
and back sections  
•
Bottom position  
1. Install front observation port assembly:  
•
blue-tipped HXT-bar, 34 inches long —  
place on the first row of pins below the  
bottom cleanout plate boss.  
a. Apply 1/8" continuous bead of sealing rope adhesive in groove  
on observation port.  
Figure 12 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)  
12  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
(continued)  
Complete block assembly  
DO NOT insert a bottom HXT-bar into the opening  
between the FRONT section and the first intermediate  
section.  
Figure 13 Cleanout plate assembly  
3. To remove ue HXT-bars when required to clean the boiler  
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.  
1. See Figure 13.  
2. Position two ¼" x 1¾" carriage bolts in cleanout opening, be-  
tween the cleanout plate bosses, as shown. Secure with washers  
and nuts.  
3. Place woven fiberglass gasket over carriage bolts.  
4. Mount cleanout plate over opening. Secure with nuts and wash-  
ers.  
5. Repeat steps 1 through 3 for remaining cleanout plates.  
Install draft hood collar  
1. Install 1/8" continuous bead of sealing rope adhesive in groove on  
draft hood collar.  
The boiler contains ceramic fiber and  
2. Position ½" sealing rope in groove. Overlap ends of rope at least  
1 inch.  
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.  
3. Mount collar over ueway outlet on back section. Secure with ½  
x 1½" hex head cap screws and washers.  
Part No. 550-100-068/0308  
13  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Connect water boiler piping  
General water piping information  
Figure 14 Water boiler piping, typical  
1. System water supply and return piping should be installed and  
piping connections attached to boiler before erecting jacket or  
installing controls.  
2. Do not pipe in through supply and out through return. This creates  
reverse water ow through boiler that must not be used.  
3. When installing in a system in which return water temperature can  
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.  
1. Connect supply and return piping:  
a. Size according to tables below.  
•
For known flow rates or higher flow rate (less than 20°F  
temperature rise) through boiler, see Figure 15.  
•
For unknown flow rates, 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.  
b. Locate circulator in supply piping.  
c. For return piping, use full diameter pipe for 10 times that  
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.  
Figure 15 Recommended minimum pipe sizes for  
known flow rates (note 1)  
d. Install system blow-off (drain) valve in lowest part of return  
piping close to boiler. ASME minimum size requirements are  
given in Figure 17, page 15.  
Water flow rate Supply pipe size  
Return pipe size  
GPM  
Up to 35  
36–50  
A
B
2"  
2"  
2½"  
3"  
2. Install expansion tank:  
2½"  
3"  
a. Closed type – 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.  
51–77  
78–142  
143–237  
238–404  
4"  
4"  
5"  
5"  
b. Diaphragm type – Refer to tank manufacturer's literature for  
6" (note 2)  
6"  
location. Install automatic air vent in "K" tapping.  
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.  
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.  
c. Connect cold water fill to expansion tank piping. 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.  
Note 2  
d. Also shown are recommended valves and water meter, when  
used.Water meter will detect added make-up water, indicating  
leaks in system.  
14  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
(continued)  
Connect water boiler piping  
Figure 16 Recommended minimum pipe sizes when flow rate is  
Figure 18 By-pass piping for return water less than  
not known (see Figure 14, page page 14) (note 1)  
140°F  
Boiler  
model  
Supply pipe size  
Return pipe size  
A
B
488  
3"  
4"  
3"  
4"  
588 – 788  
888 – 1188  
1288 – 1888  
5"  
5"  
6" (note 2)  
6" (note 2)  
By-pass circulator sizing:  
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.  
1. Size system circulator as required. Determine GPM  
and head requirements.  
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.  
2. Provide a by-pass circulator for EACH boiler. The ow  
rate for each by-pass circulator will be:  
Flow = ¼ x (System circulator GPM) ÷ (# of boilers)  
3. All circulators must run at the same time.  
Figure 17 ASME drain valve size  
4. Example: For a 1,000,000 Btuh single boiler, with  
system temperature drop of 20°F:  
Boiler  
model  
Minimum blow-off  
valve size  
• System GPM = 1,000,000 ÷ 20 ÷ 500 = 100 GPM  
• By-pass GPM = ¼ x 100 GPM = 25 GPM  
488 – 588  
688 – 1088  
1188 – 1888  
1"  
• Determine by-pass circuit head loss for pipe size  
and fittings used.  
1¼"  
1½"  
5. In most applications, a standard booster pump should  
be adequate.  
Piping multiple boilers  
1. See Figure 18. (Expansion tanks, relief valves and other accessories  
are required, but omitted from the illustration for simplicity.)  
Figure 19 Multiple water boiler piping  
2. The boiler piping circuits are referred to as the secondary circuits  
in the following.  
3. The legend for Figure 18 and boiler pump sizing recommenda-  
tions follow:  
A
Size boiler pump GPM based on the following:  
a  Temp rise = High limit temp – Return water temp  
Boiler Gross Output, Btuh  
b  GPM =  
Temperature rise x 500  
c. Calculate only secondary (boiler) piping circuit resistance. Al-  
low for head loss through the boiler equal to three 90 degree  
elbows of secondary pipe size.  
d. Operate each boiler and its pump with a Weil-McLain boiler  
control panel.  
e. Size secondary (boiler) circuit piping using the ow rate ranges  
given in Figure 17, page 15.  
B Primary pump GPM and head calculation should not include  
secondary boiler circuits. Primary pump can operate continuously  
during heating season.  
C Connection to primary circuit — Space 12" maximum or as close  
as practical.  
D Check valve.  
E
Hand valve.  
Part No. 550-100-068/0308  
15  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Connect steam boiler piping  
General steam piping information:  
Figure 20 Cold water fill piping  
1. Hartford loop piping arrangement and wet return are required for  
steam boilers. Use the Hartford loop for both pumped-return and  
gravity-return systems.  
2. Maintain 24-inch minimum from waterline to bottom of header (63"  
from bottom of section).  
3. When using condensate receiver, feed pump must be energized by  
boiler-mounted pump controller.  
4. Install piping:  
a. Install piping as shown on page 17 through page 18 for single boil-  
ers. See page 19 for additional requirements when piping multiple  
boilers.  
b. Return pipe sizing.  
•
•
Pumped return — Size return piping by pump.  
Gravity return — Size gravity return same as Hartford loop  
equalizer pipe size.  
Figure 21 Condensate piping to boiler  
c. Drain valve — Install system drain valve in lowest part of return  
piping close to boiler. See Figure 17, page 15, for sizing.  
d. Cold water fill piping — Connect cold water fill piping as shown in  
Figure 20. Also shown are recommended valves and water meter,  
if used. Water meter will detect added makeup water, indicating  
leaks in system.  
e. Condensate return piping:  
•
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.  
Figure 22 Condensate receiver capacity required  
Boiler  
I=B=R gross output Gallons condensate  
Minimum condensate receiver capacity (gallons) (Note 1)  
Recommended condensate  
model number  
(lbs steam per hour)  
per hour  
feed pump capacity  
GPM at 15 PSI  
15-minute boiler  
operation  
30-minute boiler 45-minute boiler 60-minute boiler  
operation  
operation  
operation  
488  
488R  
588  
810  
97  
29  
28  
58  
87  
116  
114  
156  
196  
234  
273  
313  
289  
353  
332  
392  
432  
470  
511  
550  
588  
574  
629  
668  
3.2  
3.1  
794  
95  
57  
85  
1084  
1358  
1632  
1904  
2170  
1991  
2452  
2304  
2724  
3000  
3270  
3550  
3820  
4090  
3980  
4370  
4640  
130  
163  
195  
228  
261  
239  
294  
277  
327  
360  
392  
426  
458  
490  
478  
524  
557  
39  
78  
117  
147  
176  
205  
235  
217  
265  
249  
294  
324  
353  
383  
412  
441  
430  
471  
501  
4.3  
688  
49  
98  
5.4  
788  
59  
117  
137  
157  
145  
176  
166  
196  
216  
235  
255  
274  
294  
287  
314  
334  
6.5  
888  
68  
7.6  
988  
78  
8.7  
988R  
1088  
1088R  
1188  
1288  
1388  
1488  
1588  
1688  
1688R  
1788  
1888  
72  
8.0  
88  
9.8  
83  
9.2  
98  
10.9  
12.0  
13.1  
14.2  
15.3  
16.4  
15.9  
14.5  
18.6  
108  
117  
127  
137  
147  
143  
157  
167  
Note 1 — Maximum time to when condensate returns to boiler — the longer the time for condensate to return, the larger the receiver must be.  
16  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
(continued)  
Connect steam boiler piping  
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.  
Figure 23 Model 488 through 688 steam (1 riser)  
Steam boiler piping guidelines  
Minimum height of header above water line must  
be 24 inches  
The boiler header must always be at least 24 inches  
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  
1. You must install the system supply pipe between the equalizer  
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.  
2. Locate the top of the Hartford loop return nipple at least 4 inches  
below the water line, as shown.  
Figure 24 Model 788 through 1188 steam (2 risers required)  
Drawing legend & notes  
(Figure 23 through Figure 26)  
1
2
Riser pipes (one for each supply intermediate  
section)  
Horizontal pipes needed to offset the header  
to allow for expansion and contraction of the  
header  
3
Steam supply must be located between last riser  
connection and equalizer elbow  
4
5
6
Equalizer elbow — full size or reducing  
Equalizer pipe  
Close nipple at Hartford loop tee to reduce water  
hammer potential  
7
8
Condensate return line (gravity or pumped)  
Minimum 4 inches between water line and top  
of Hartford loop return nipple  
9
Boiler water line — all automatic water level  
controls must be set to maintain this level  
10 Minimum 24 inches between water line and  
bottom of header  
Part No. 550-100-068/0308  
17  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
(continued)  
Connect steam boiler piping  
Figure 25 Model 1288 through 1888 steam (3 or 4 risers required)  
Drawing legend & notes  
(Figure 23 through Figure 26)  
1
2
3
4
5
6
7
8
9
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  
10 Minimum 24 inches between water line and bottom of header  
18  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
(continued)  
Connect steam boiler piping  
Figure 26 Multiple Steam Boiler Piping Gravity Condensate Return  
See page 18 for numbered  
circle references.  
A
Pipe as shown for gravity return systems, connect-  
D Install stop valves per ASME code requirements.  
ing point A to the wet gravity return.  
•
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.  
•
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  
E
F
Construct common supply drop header with pipe  
size at least same size as largest boiler header size.  
boiler, or . . .  
Single feed pump, with separate solenoid valve  
for each boiler.  
Use:  
•
•
A Weil-McLain Boiler Control System (such as  
a BCP panel) with header-mounted pressure  
control(s) to sequence boilers, or . . .  
B For pumped-return systems, install a combination  
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.  
A steam pressure controller.  
G Install drip line in common supply drop header.  
Gravity-return systems are self-levelling if the wet  
returns are piped to the common system wet return.  
•
•
Gravity-return: Pipe drip line to wet return.  
Pumped-return: Use combination oat and  
thermostatic trap and drain to condensate  
receiver.  
C Install boiler piping as shown in the preceding pages  
of this manual.  
Part No. 550-100-068/0308  
19  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Install jacket  
Before installing jacket  
Figure 27 Place support brackets as listed below  
The boiler contains ceramic fiber and fiberglass materials.  
Boiler  
Upper brackets on  
Lower brackets  
on sections:  
None  
Use care when handling these materials per instructions  
on page 34 of this manual. Failure to comply could result  
in severe personal injury.  
sections:  
2, 3  
2, 4  
2, 5  
2, 6  
488  
588  
688  
788  
888  
988  
None  
None  
None  
None  
1. These parts must be on boiler:  
3, 6  
2, 5, 8  
a. Plugs for unused tappings  
b. Supply and return piping and steam supply header  
c. Cleanout plates  
d. Tankless heaters (when used), tankless heater cover plates  
(when used), tankless heater piping (when used)  
e. Flue damper assembly  
None  
1088  
1188  
1288  
1388  
1488  
1588  
1688  
1788  
1888  
3, 6, 9  
3, 6, 9  
3, 7, 10  
6
6
7
7
7
8
9
9
10  
3, 7, 11  
3, 7, 10, 13  
2, 5, 8, 11, 14  
2, 5, 9, 12, 15  
2, 5, 9, 13, 16  
2, 6, 10, 14, 17  
f. Observation port assemblies  
2. These parts may be on boiler:  
a. Burner mounting plate and burner  
3. These parts must be off boiler:  
a. Water or steam gauge  
3. Attach the upper channels to the upper supports as  
shown in callouts and , Figure 29, page 21.  
,
b. Limit control and low water cutoff  
c. Gauge glass and gauge glass cocks, tri-cocks  
d. Drain cock  
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.  
Remove jacket parts from cartons  
•
The channels at the boiler front and rear are  
part numbers 426400030 & 426400031, re-  
spectively.  
1. Locate jacket cartons.  
2. Remove jacket parts from cartons as needed. Leave in cartons as  
long as possible to avoid damage.  
Figure 28 Upper and lower side channel lengths  
3. Jacket parts are in the boxes listed below:  
Boiler  
Upper channel lengths  
Lower channel lengths  
Part  
Box label descriptions  
included in CRNR boxes  
BKT  
(inches)  
(inches)  
Jacket screws (in jacket corner boxes)  
Jacket support brackets & hex nuts  
Jacket side support channels, upper & lower  
Jacket front/rear support channels, upper & lower  
Jacket front panel  
A
B
A
B
488  
588  
688  
788  
888  
30  
38  
46  
54  
62  
NA  
NA  
NA  
NA  
NA  
26  
34  
42  
50  
58  
NA  
NA  
NA  
NA  
NA  
included in TRM/CHNL boxes  
COM  
988  
35  
35  
66  
NA  
PNL-F  
1088  
1188  
1288  
1388  
1488  
1588  
1688  
1788  
1888  
43  
43  
51  
51  
51  
59  
67  
67  
71  
35  
43  
43  
51  
59  
59  
59  
67  
71  
40  
40  
48  
48  
48  
56  
64  
64  
72  
34  
42  
42  
50  
58  
58  
58  
66  
66  
Jacket back panel  
PNL-B  
Jacket side and top panels  
Jacket corners  
L / R / T  
CRNR  
Jacket trim  
TRM/CHNL  
Install support brackets/channels  
4. Attach the four jacket corners to the upper channels  
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).  
1. Place upper and lower support brackets over draw rods as shown  
in Figure 29, page 21. Place the brackets on the sections as given in  
Figure 27. Sections are numbered from front to back.  
2. Fasten each bracket loosely using two 5/8" nuts screwed onto the  
ends of the tie rods as shown.  
5. Attach the lower side, front and rear channels to  
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.  
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.  
20  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
(continued)  
Install jacket  
Figure 29 Installing jacket support brackets, support channels and corners (piping and other components omitted for clarity)  
Part No. 550-100-068/0308  
21  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
(continued)  
Install jacket  
Install jacket front and back panels  
1. Slide the jacket front and back panels down over the top channels  
and into the bottom channels as shown in Figure 30.  
Figure 30 Installing (removing) jacket front, rear  
and side panels  
2. Slide the upper and lower channels as needed to square up the  
fit.  
Install jacket side panels  
1. Remove jacket side panels from cartons.  
2. Before installing side panels, square up the jacket support rails.  
•
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.  
•
•
•
•
3. Apply all jacket side panels in the order shown in 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  
1. Place jacket top panels as shown in Figure 33, page 24.  
•
Remove knockouts for riser pipes and air bleed piping (front  
section) using tin snips.  
Figure 31 Press jacket trim down over jacket front,  
rear and side panels  
Install jacket trim  
2. Press jacket trim down over the front and side jacket panels as  
shown in Figure 31.  
22  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
(continued)  
Install jacket  
Figure 32 Jacket side panel placement  
Part No. 550-100-068/0308  
23  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
(continued)  
Install jacket  
Figure 33 Jacket top panel placement  
24  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Pipe tankless heaters  
To pipe tankless heaters:  
1. See Figure 35.  
2. Size piping no smaller than heater inlet and out-  
let.  
Hot water can scald!  
3. Automatic mixing valve must be installed. See  
Figure 35. Follow manufacturer's instructions to  
install.  
4. Flow regulating valve must be installed. Size accord-  
ing to continuous draw of heater. See Figure 34.  
Follow manufacturer's instructions to install.  
5. Operating control with small adjustable differen-  
tial scale is recommended. Install in temperature  
control tapping in heater plate.  
6. Multiple tankless heaters (see Figure 35):  
a. Use cold water supply header with individual  
risers to each heater. Size header by increasing  
one pipe size for each additional heater.  
b. Use hot water outlet header with individual  
risers to each heater. Size header by increasing  
one pipe size for each additional heater.  
c. Do not pipe multiple heaters in series.  
7. In hard water areas, soften cold domestic water  
supply to heaters to prevent lime build-up.  
Consumer Product Safety Commission and some  
states recommend domestic hot water tempera-  
ture of 130°F or less.  
Figure 34 Tankless heater ratings (Weil-McLain  
ratings)  
When installing an automatic mixing valve, se-  
lection and installation must comply with valve  
manufacturer's recommendations and instruc-  
tions.  
Heater  
number  
Intermittent  
draw – GPM  
(note 2)  
Continuous  
draw GPM  
(notes 1, 2)  
Inlet and  
outlet tappings  
820  
8.5  
6.5  
¾"  
GPM based on 40–140°F DHW with boiler water  
at 200°F  
Note 1  
Note 2  
Water heated to a temperature suitable for clothes  
washing, dish washing and other sanitizing needs  
will scald and cause injury.  
Based on continuous draw with no recovery period  
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:  
Figure 35 Tankless Heater Piping  
— 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.  
Part No. 550-100-068/0308  
25  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Install water boiler controls  
Install controls:  
Figure 37 Water control locations  
1. Install furnished controls per 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.  
2. Relief valve must be installed with spindle in vertical position. Use  
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.  
3. When installing low water cut-off  
a. Must be installed if boiler is located above radiation level.  
b. May be required on water boilers by certain state, local or ter-  
ritorial codes or insurance companies.  
c. Install low water cutoff designed for water installations where  
shown in Figure 36 and Figure 37.  
4. If installation is to comply withASME installation requirements,an  
additional high temperature limit is needed. Purchase and install in  
supply line between boiler and isolation valve or in tapping "A."  
5. Dual limit control settings:  
a  Low – set according to design requirements.  
b  High – at least 20° higher than low limit, 240°F maximum.  
6. Install optional controls per control manufacturer's instructions.  
Figure 36 Water control tappings (see Figure 37)  
Location  
Size  
Function  
A
2"  
High limit  
Manual reset limit  
B
L
2"  
1"  
1"  
Water relief valve  
Not used — plug  
C1 & C2  
C1  
Alternate low water cut-offs  
Combination high and low  
limit control  
D1 & D2  
1"  
Firing rate temperature  
control (when used)  
Low water cut-offs  
E1 & E2  
½"  
C\,"  
¾"  
¾"  
1"  
—
F1 & F2  
—
G
H
K
Combination pressure–temperature gauge  
Boiler drain  
Piping to compression tank or automatic air vent  
26  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Install steam boiler controls  
Install controls:  
Figure 39 Steam control locations  
1. Install controls where shown in 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.  
a. Install steam pressure operating and high limit controls and  
pressure gauge. See Figure 38, Figure 39 and Figure 40, page 28.  
Pressure limit control settings:  
•
•
Low – set according to design requirements.  
High – set at least 2 psi higher than low limit, 15 psi maxi-  
mum.  
b. Relief valve must be installed with spindle in vertical position.  
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.  
c. Install water level controls and gauge glass per 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.  
Figure 38 Steam control tappings (see Figure 39)  
Location  
Size  
Function  
A
2"  
Steam relief valve and/or  
Skim tapping  
B
2"  
1"  
1"  
Steam relief valve  
L
Secondary probe low water cut-off  
C1 & C2  
C1  
Low water cut-offs (see Figure 42, page 28)  
—
D1 & D2  
E1 & E2  
F1 & F2  
G
1"  
½"  
C\,"  
¾"  
Alternate low water cut-offs (see Figure 42, page 28)  
Gauge glass  
Try cock tappings  
Pressure limit control,  
Pressure operating control and pressure gauge,  
Firing rate pressure control (when used)  
H
K
¾"  
1"  
Boiler drain (see Figure 17, page page 15, for system  
blow-off (drain) valve locations and sizes  
—
Part No. 550-100-068/0308  
27  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
(continued)  
Install steam boiler controls  
Figure 40 Steam control siphon and fittings  
Figure 41 Float-type water level control locations  
Primary water level  
control  
Casting line  
height above  
bottom of gauge  
glass  
Back-up water level  
control  
Casting line  
height above  
bottom of gauge  
glass  
Note 1  
"A"  
¼"  
Notes 1, 2  
None  
"B"  
—
61, 63  
1½"  
2C\,"  
2"  
61, 63  
½"  
—
None  
150  
¼"  
¼"  
¼"  
—
150MD, 157MD  
(see Note 3)  
2C\,"  
2C\,"  
2"  
61, 63  
51-2 & 51-S-2  
None  
2"  
93, 193, 94  
61, 63  
¼"  
¼"  
¼"  
93, 193, 94  
(see Note 3)  
2"  
2"  
51-2 & 51-S-2  
51-2 & 51-S-2  
(see Note 3)  
1"to 1¼"  
None  
—
Notes:  
1. Other manufacturer's controls providing similar function may be used, if properly  
located and selected.  
2. Use low water cut-off function only. Pump controller function must only be handled  
by the primary control.  
3. When pump control is used with feedwater tank, install pump control on boiler and  
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.  
Figure 42 Water level control locations (see Figure 41)  
28  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Connect breeching and venting systems  
General venting information  
Figure 43 Minimum breeching diameter  
1. Model 88 boilers operate with positive overfire pressure. Adjust  
damper assembly (see Figure 49, page 33) during burner start-up  
to achieve 0.1" W.C. positive pressure at damper sample hole.  
Boiler  
model  
I=B=R  
vent or liner diameter  
(inches)  
Boiler flue  
collar  
dimensions  
(inches)  
Select type of venting system  
Forced  
draft  
Balanced  
draft  
Forced draft  
•
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.  
10  
10  
12  
12  
14  
14  
14  
16  
16  
16  
18  
18  
18  
18  
20  
12  
15  
15  
18  
18  
18  
21  
21  
21  
24  
24  
24  
24  
24  
27  
10 round  
10 round  
488  
588  
Balanced draft  
10 round  
688  
•
Boiler operates with positive pressure overfire. Chimney may  
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.  
12 round  
788  
12 round  
888  
14 round  
988  
Construct metal breeching:  
14 round  
1088  
1188  
1288  
1388  
1488  
1588  
1688  
1788  
1888  
1. See Figure 43 for minimum breeching diameter.  
14 round  
2. Select material type and thickness in compliance with local  
codes.  
14 round  
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.  
14 round  
16 round  
3. Refer to ASHRAE Guide for chimney and breeching calculations  
and construction and lining.  
16 round  
16 round  
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.  
16Z\, x 19M\, oval  
16Z\, x 19M\, oval  
Part No. 550-100-068/0308  
29  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Connect breeching and venting systems  
Figure 44 Stub vent – forced draft — single boiler  
Figure 46 Stub vent – forced draft — multiple  
boilers  
Figure 45 Conventional chimney – balanced draft  
with barometric draft control when  
required — single boiler  
Figure 47 Conventional chimney – balanced draft  
with barometric draft control when  
required — multiple boilers  
30  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Install burner & wiring and fill system  
For unusually hard water areas or low pH conditions  
To install burner  
(less than 7.0) consult local water treatment company.  
Provide a water softener for make-up water if hardness  
exceeds 7 grains.  
1. Unpack burner.  
2. Place gasket around air tube and against burner mounting ange.  
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.  
Freeze protection (when used)  
(water boilers only)  
3. Mount burner into opening in burner mounting plate.  
1. Use antifreeze especially made for hydronic systems.  
Inhibited propylene glycol is recommended.  
Maintain gas-tight seal between burner mounting ange  
and plate to prevent damage to air tube.  
4. Level burner using burner support brackets where required.  
5. Secure with furnished bolts.  
Do not use automotive, ethylene glycol  
or undiluted antifreeze. Severe personal  
injury or death can result.  
6. Retain burner information packet. Keep with boiler.  
2. 50% solution provides protection to about -30°F.  
3. Local codes may require back- ow preventer or  
actual disconnect from city water supply.  
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.  
4. Determine quantity according to system water  
content. Boiler water content is listed in "Ratings,"  
page 35. Percent of solution will affect sizing of heat  
distribution units, circulator and expansion tank.  
1. Install all wiring in compliance with:  
5. Follow antifreeze manufacturer's instructions.  
•
•
National Electrical Code ANSI/NFPA 70.  
Any additional national, state, or local codes.  
2. Follow burner manual and wiring diagram found in burner in-  
formation packet.  
To fill water boilers  
1. Close manual air vents and drain cocks.  
3. Use #14 AWG wire for operating and safety circuit wiring.  
2. Fill to correct system pressure. Correct pressure will  
vary with each installation.  
4. Where burner motor voltage differs from control voltage, supply  
proper voltage to each. Size fused disconnects and conductors per  
National Electrical Code ANSI/NFPA 70.  
3. Starting on lowest oor, open air vents one at a  
time until water squirts out. Close vent. Repeat  
with remaining vents.  
Determine if water treatment is needed  
(water boilers only)  
4. Refill boiler to correct pressure.  
Do not use petroleum-based cleaning or sealing com-  
pounds in boiler system. Severe damage to system  
components can result, causing substantial property  
damage.  
To fill steam boilers  
1. Do not fill (except for leakage test) until boiler is  
ready to be fired.  
Continual make-up water will reduce boiler life. Minerals can build up  
in sections, reducing heat transfer, overheating cast iron and causing  
section failure.  
2. Fill to normal waterline, halfway up gauge glass.  
3. Recommend boiler water pH 7.0 to 8.5.  
Part No. 550-100-068/0308  
31  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Install fuel piping  
Gas piping  
Figure 48 Gas supply piping  
1. In sizing the gas piping, the following factors should be consid-  
ered:  
a. Diameter and length of the gas supply piping.  
b. Number of fittings.  
c. Maximum gas consumption (including any possible future  
expansion).  
d. Allowable loss in gas pressure from the gas meter outlet to  
the boiler.  
2. Minimum inlet natural gas pressure required at manual main shut-  
off valve — see the burner manual and material list.  
3. Follow good piping practices.  
4. Pipe joint compound (pipe dope) must be resistant to the corrosive  
action of liquefied petroleum gases and applied sparingly only to  
the male threads of pipe joints.  
5. A ground joint union must be installed in the piping to provide  
for servicing. The supply piping must include a manual shut-off  
valve and sediment trap. See Figure 48.  
6. Piping must be supported by hangers, not by the burner or its  
accessories.  
7. Purge all air from the supply piping.  
8. All gas piping must be tested for leaks after installation. Use soap  
suds mixture only.  
Fuel oil piping  
To prevent oil ow in case of oil line breakage:  
7. Follow good piping practices.  
8. Pipe joint compound (pipe dope) must be resistant  
to corrosive action of fuel oil. Apply sparingly only  
to male threads of pipe joints.  
•
Use anti-syphon device when any part of the oil tank  
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.  
9. Supply and return piping should be sized to design  
conditions, but not less than ½" O.D. continuous  
copper tubing.  
Failure to comply could result in fuel leakage or fire, caus-  
ing potential severe personal injury, death or substantial  
property damage.  
10. Auxiliary fuel oil pump is recommended when  
suction line lift exceeds 12 feet.  
11. Install swing joints so they will tighten as buried  
tank settles to prevent fuel line breakage.  
1. A two-pipe fuel oil piping system is required for all installations.  
2. Supply and return lines must enter tank from top, extending to  
within 4 to 6 inches from bottom of tank.  
12. Where iron pipe is required by local codes, make  
swing joints with nipples and elbows several inches  
long on both suction and return line. Locate close  
to tank.  
3. Use oil filter sized for fuel pump suction gear capacity.  
4. Install oil filter.  
Do not install filter outside or close to an outside wall.  
13. Install manual shut-off valve in suction line piping  
near burner and where piping enters building from  
outside tank.  
5. Use continuous copper tubing to reduce possible piping leaks and  
to ensure reliable seal when oil piping is buried.  
14. Pitch suction line piping toward fuel tank.  
6. Use are fittings, not compression fittings.  
15. Provide tee and plug at highest point in suction  
line to release air from suction line and aid in  
priming.  
Fire hazard — DO NOT USE soldered fittings. No safe  
repair can be made.  
32  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Make final adjustments  
Adjust burner and damper assembly:  
Figure 49 Flue collar/damper assembly  
1. Lock ue damper OPEN (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.  
2. Refer to burner manual for start-up and service.  
3. Let burner advance to high fire. Heat boiler to design conditions.  
4. Using combustion test equipment, adjust burner for:  
a. 12% ( ¼%) CO2 for No. 2 fuel oil, 0 smoke.  
b. 9 – 10% CO2 natural gas; CO in ue gas not to exceed 50 ppm  
(0.01%).  
c. Flue gas temperature no lower than 330°F  
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).  
8. Drain boiler.  
9. While boiler is warm, but not hot, ush all inte-  
rior surfaces under full pressure until drain water  
runs clear.  
5. Adjust ue collar damper (Figure 49) to ensure 0.1" W.C. positive  
pressure at test opening.  
6. Tighten screws to secure in position.  
10. Remove skim piping.  
7. Plug test opening with 1/8" plug provided with ue collar/damper  
assembly.  
11. Re-insert plug at boiler skim tapping.  
12. Close drain cock.  
8. Adjust barometric draft control, when used, to design condi-  
tions.  
13. Fill with fresh water to normal water line.  
9. Repeat steps 4 through 6. Adjust as required.  
14. Start burner and steam for 15 minutes to remove  
dissolved gases.  
Skim steam boilers:  
15. Stop burner.  
16. Check traps and air vents for proper operation.  
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.  
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.  
Do not use petroleum-based cleaning or sealing com-  
pounds in boiler system. Severe damage to system  
components can result, causing substantial property  
damage.  
1. Remove boiler jacket side and top panels.  
1. Remove 2" plug from skim tapping tapping "A" (see Fig-  
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.  
ure 38, page 27).  
2. Provide 2" skim piping from tapping to oor drain.  
3. Raise waterline to midpoint of skim piping.  
4. Fire burner to maintain temperature below steaming rate during  
skimming process.  
2. Start burner. Observe all sealing points and chalk  
mark any not gas-tight.  
5. Feed in water to maintain water level.  
3. To seal all chalk-marked areas:  
6. Cycle burner ON/OFF as needed to prevent rise in steam pres-  
sure.  
a. Use silicone sealant on section ueways.  
b. Check gaskets and sealing rope placement.  
4. Reinstall all jacket panels.  
7. Continue skimming until discharge is clear. This may take several  
hours.  
Part No. 550-100-068/0308  
33  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
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.  
•
Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA re-  
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.  
•
Wear long-sleeved, loose fitting clothing, gloves, and eye protection.  
■
■
■
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.  
•
Use NIOSH certified dust respirator (N95). This type of respirator is based on the 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.  
•
Wear long-sleeved, loose fitting clothing, gloves, and eye protection.  
■
■
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.  
34  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
Ratings  
Boiler  
model  
number  
I=B=R  
burner  
capacity  
Gross  
I=B=R  
output  
Net I=B=R ratings  
Boiler Combustion  
H.P.  
Thermal  
efficiency  
Net  
firebox  
Flue  
gas  
Positive Flue  
pressure outlet  
Boiler Packaged  
water boiler  
efficiency  
volume volume in firebox diameter content weight  
Light oil Gas  
GPH  
MBH Steam Steam Water  
Sq. Ft MBH  
Oil  
Gas  
Oil  
Gas  
Cubic  
feet  
CFM  
Inches  
W.C.  
Inches Gallons Pounds  
MBH  
MBH  
Notes:  
1, 10  
2, 3  
2, 4  
5, 6  
8
8
8
—
—
—
—
—
—
7
9
—
—
—
488R  
488  
6.9  
7.0  
996  
827  
839  
2,583  
2,621  
620  
629  
845  
719  
730  
979  
24.7  
25.1  
33.6  
87.5  
87.5  
87.0  
86.7  
86.5  
86.3  
86.2  
86.2  
86.2  
86.2  
86.1  
86.0  
84.8  
84.8  
84.4  
84.1  
83.9  
83.7  
83.7  
83.7  
83.6  
83.6  
83.5  
83.5  
84.4  
83.4  
83.3  
83.3  
83.3  
83.3  
83.3  
85.6  
85.6  
85.6  
85.6  
85.6  
85.6  
85.6  
85.6  
85.6  
85.6  
85.7  
85.7  
85.7  
85.7  
85.7  
85.7  
85.7  
85.7  
85.7  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
83.1  
11.02  
11.02  
14.45  
18.08  
21.61  
25.14  
28.67  
28.67  
32.20  
32.20  
35.76  
39.26  
42.79  
46.32  
49.85  
53.38  
53.38  
56.91  
60.44  
376  
370  
0.60  
0.60  
0.63  
0.65  
0.67  
0.69  
0.70  
0.70  
0.71  
0.71  
0.72  
0.73  
0.74  
0.75  
0.76  
0.77  
0.78  
0.79  
0.80  
10  
10  
10  
10  
12  
12  
14  
14  
14  
14  
14  
14  
14  
16  
16  
16  
16  
18 *  
18 *  
109  
109  
132  
155  
178  
201  
224  
224  
247  
247  
270  
293  
316  
339  
362  
385  
385  
408  
431  
2860  
2860  
3340  
3820  
4345  
4925  
5600  
5600  
6130  
6130  
6695  
7260  
7890  
8410  
9005  
9525  
9525  
9780  
10775  
1,010  
1,356  
1,701  
2,046  
2,382  
2,482  
2,737  
2,887  
3,082  
3,428  
3,773  
4,119  
4,464  
4,809  
4,979  
5,155  
5,494  
5,845  
588  
9.4  
1,126 3,521  
507  
688  
11.8  
14.2  
16.6  
17.2  
18.8  
1,413 4,469 1,072 1,229 42.2  
1,700 5,463 1,311 1,478 50.8  
1,987 6,427 1,543 1,728 59.4  
2,062 6,671 1,601 1,793 61.6  
2,274 7,358 1,766 1,977 67.9  
2,399 7,763 1,863 2,086 71.7  
2,561 8,283 1,988 2,227 76.5  
2,848 9,213 2,211 2,477 85.1  
3,135 10,147 2,434 2,726 93.7  
639  
788  
772  
888  
906  
988R  
988  
1,031  
954  
1088R 20.0  
1,184  
1,101  
1,299  
1,443  
1,588  
1,735  
1,854  
2,003  
1,945  
2,152  
2,303  
1088  
1188  
1288  
1388  
1488  
1588  
21.5  
23.5  
26.0  
28.5  
31.0  
33.0  
3,422 11,071 2,657 2,976 102.2 86.0  
3,709 12,000 2,880 3,225 110.8 86.0  
3,996 12,925 3,102 3,475 119.4 85.9  
4,137 13,383 3,212 3,597 123.6 85.9  
4,283 13,854 3,325 3,724 127.9 85.9  
4,570 14,783 3,548 3,974 136.5 85.9  
4,857 15,713 3,771 4,123 145.1 85.9  
1688R 34.5  
1688  
1788  
1888  
35.5  
38.0  
40.5  
5. Gross I=B=R ratings have been determined under the I=B=R provision  
governing forced draft boiler-burner units.  
1. See below to specify complete model number.  
6. Based on average water temperature of 170°F in heat distributing  
units.  
7. Flue gas volume at outlet temperature.  
8. Net I=B=R ratings are based on net installed radiation of sufficient  
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.  
2. Burner input based on maximum of 2,000 feet altitude. For other  
altitudes, consult Weil-McLain distributor/agent or sales office.  
Consult local Weil-McLain distributor/agent or sales office.  
3. No. 2 fuel oil — Commercial Standard Spec CS75-56. Heating  
value of oil = 140,000 Btu per gallon.  
9. With 0.10" W.C. positive pressure at flue collar.  
10. Water boilers tested for 80 PSIG, ASME water working pressure.  
Steam boilers tested for 15 PSIG, ASME steam working pressure.  
4. Gas pressure required at burner gas train inlet for rated burner  
input; based on 1,000 Btu per cubic foot natural gas, specific  
gravity of 0.60. Refer to burner manual for required pressure.  
*
Flue collar connection is oval, 16Z\," x 19M\,"  
Part No. 550-100-068/0308  
35  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Dimensions  
Dimensions (inches)  
Model  
A
B
C
D
E
L
W
H
488  
588  
23  
31  
—
—
—
—
10  
10  
10  
12  
12  
14  
14  
14  
14  
14  
16  
16  
16  
54¾  
54¾  
54¾  
53¾  
53¾  
52¾  
52¾  
52¾  
52¾  
52¾  
51¾  
51¾  
51¾  
51¾  
51¾  
34¾  
42¾  
30  
38  
23C\,  
31C\,  
39C\,  
47C\,  
55C\,  
63C\,  
71C\,  
79C\,  
87C\,  
95C\,  
103C\,  
111C\,  
119C\,  
127C\,  
135C\,  
688  
39  
—
—
50¾  
46  
788  
47  
—
—
58¾  
54  
888  
55  
—
—
66¾  
62  
988  
63  
—
—
74¾  
70  
1088  
1188  
1288  
1388  
1488  
1588  
1688  
1788  
1888  
71  
—
—
82¾  
78  
79  
—
—
90¾  
86  
87  
39½  
47½  
55½  
63½  
47½  
31½  
39½  
—
98¾  
94  
95  
—
106¾  
114¾  
122¾  
130¾  
138¾  
146¾  
102  
110  
118  
126  
134  
142  
103  
111  
119  
127  
135  
—
—
—
79½  
87½  
16Z\," x 19M\,"  
oval  
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  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
3 – 5"  
3 – 5"  
3 – 5"  
3 – 5"  
3 – 5"  
3 – 5"  
4 – 5"  
4 – 5"  
Water  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
2 – 5"  
Steam  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
Water  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
1 – 6"  
488R  
488  
21  
21  
21  
21  
21  
21  
21  
26  
26  
26  
26  
26  
26  
26  
—
—
—
—
—
33  
33  
33  
33  
33  
49  
49  
49  
49  
49  
49  
49  
49  
49  
49  
49  
49  
49  
56  
31  
31  
31  
34  
34  
34  
34  
34  
34  
34  
39  
39  
39  
39  
39  
39  
39  
44  
44  
21  
21  
21  
22  
22  
22  
22  
22  
22  
22  
23  
23  
23  
—
—
—
—
—
—
29  
30  
30  
30  
30  
30  
30  
30  
30  
30  
30  
30  
30  
30  
—
—
—
—
—
588  
688  
788  
888  
988R  
988  
1088R  
1088  
1188  
1288  
1388  
1488  
1588  
1688R  
1688  
1788  
1888  
36  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
(continued)  
Dimensions  
Figure 50 Dimensions (see lettered dimensions on opposite page)  
Part No. 550-100-068/0308  
37  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Parts  
Item  
Description  
Part number  
1
2
Front sections (8823)  
316-301-210  
316-301-212  
Regular intermediate section (8825)  
3
Tankless intermediate section (8826)  
316-301-214  
4
Back section (8828)  
316-301-211  
—
—
5
Supply intermediate section (8824) (not shown)  
Section replacement kit (includes rope seals, rope adhesive and sealant for one joint)  
Burner mounting plate  
316-301-213  
386-300-213  
Order for specific burner  
590-735-140  
6 & 13  
7
Sealing rope — ½" (13 feet per joint, 7 feet for burner plate, 6 feet for flue collar)  
Tankless heater, when used, number 820  
Heater gasket  
590-291-909  
8
590-317-579  
9
Heater cover plate  
450-030-934  
10  
11  
12  
Draw rod 5/8"-11UNC-2A x 13" (apply to front and rear sections)  
Draw rod 5/8"-11UNC-2A x 11" (apply between intermediate sections)  
560-134-505  
560-134-495  
Draft hood collar assembly  
(includes damper collar, damper, damper quadrant, locking plate, swivel, brackets and rope)  
a. 10-inch — 488 through 688. . . . . . . . . . . . . . . . . . . . .  
340-004-606  
340-004-607  
340-004-608  
340-004-609  
340-004-612  
330-056-634  
460-003-646  
563-530-784  
b. 12-inch — 788 and 888 . . . . . . . . . . . . . . . . . . . . . . .  
c. 14-inch — 988 through 1388 . . . . . . . . . . . . . . . . . . . .  
d. 16-inch — 1488 through 1688 . . . . . . . . . . . . . . . . . . .  
e. 18-inch — 1788 and 1888 . . . . . . . . . . . . . . . . . . . . .  
f. Quadrant for flue collar . . . . . . . . . . . . . . . . . . . . . . .  
g. Damper blade . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
h. Damper locking plate . . . . . . . . . . . . . . . . . . . . . . . .  
14  
15  
Cleanout plate  
450-030-965  
590-317-305  
Woven fiberglass gasket for cleanout plate  
16 & 18  
Observation port assembly (includes frame, rope, gasket, plugs and sight glass)  
383-600-099  
591-419-199  
590-317-580  
a. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
b. Sight glass only . . . . . . . . . . . . . . . . . . . . . . . . . . .  
c. Washer gasket for sight glass (2Z\, x 1Z\v x Z\, inches) . . . . . . . .  
17  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
Sealing rope, C\," (1 foot per observation port)  
590-317-150  
Obtain locally  
Obtain locally  
Obtain locally  
Obtain locally  
Obtain locally  
Obtain locally  
Obtain locally  
Obtain locally  
Obtain locally  
Obtain locally  
Obtain locally  
Burner mounting plate studs (½ x 3½ inches)  
Cleanout plate nut, ¼"  
Cap screw, ½–13 x ¾"  
Observation port screw, 10–32 x 1½"  
Flue collar cap screw, ½" x 1½"  
Flue collar washer, ZZ\zn"  
Burner mounting plate washer, ½"  
Burner mounting plate nut, ½"  
Draw rod nut, B\,"  
Cleanout plate washer, ¼"  
Cleanout plate carriage bolt, ¼" x 1¾"  
HXT-bars (see Figure 12, page 12, for installation and placement details for HXT-bars)  
d. 3-flueway kit (includes 3 sets of bars)  
416-400-130  
416-400-131  
e. 2-flueway kit (includes 2 sets of bars)  
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  
38  
Part No. 550-100-068/0308  
Boiler manual:  
• Installation • Start-Up • Maintenance • Parts  
(continued)  
Parts  
Figure 51 Parts  
Part No. 550-100-068/0308  
39  
Weil-McLain 88 Water and steam boilers — Series 2 — for Gas, Light Oil, & Gas/Light Oil-Fired Burners  
Warranty  
April 1, 2003  
Weil-McLain Limited Warranties  
Residential & Commercial Cast Iron Boilers  
‹Residential Water Warranty — Limited Lifetime  
‹Residential Steam Warranty — Limited 10 Year  
‹Commercial Warranty — Limited 10 Year  
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)  
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%.  
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 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.  
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.  
Weil-McLain Ultra Cast Aluminum Boilers  
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.  
‹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  
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.  
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 thePlan 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.  
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  
Eleventh Through Fifteenth Year  
—
Weil-McLain warrants that the heat  
water within the pipes (tubing) does not constitute  
workmanship and shall not be covered by this warranty.  
See section “For all Weil-McLain Products” for additional warranty information.  
a
defect in material or  
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%.  
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.  
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.  
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.  
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.  
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.  
Part No. 550-141-950/0403  
40  
Part No. 550-100-068/0308  

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