Well-mcLain 68 Series User manual

UEll'flhHlil
68 and
68V oil-Fired
Boiler
Manual
lncludes:
. Installation
o Start-up
. Service
o Parts
-
68
BOILER
REAR
FLUEOUTLET
68V
BOILER
TOPFLUE
OUTLET
Anyclaims
for damageorshortage
inshipment
mustbefiledimmediatelyagainst
the
transportation
company
bytheconsignee.
J
Part
No.
550-1
10-49410487WP

-ffi-
Table
ofContents
AirSupply
forCombustion
.. .. WiringDiagram '.'.15
Chimney
or
VentRequirements J
4
4
Standard
Minimum
Clearances
BoilerFoundaton
WaterTreatment... ......16
Freeze
Protection
FillingWaterBoilers .......16
FillingSteamBoilers ......16
BurnerAdjustment ........16
Skimming
Steam
Boilers
.... ..... 16
Check-OutList... ........17
lnstallationandServiceCertificate ....... 17
16
21
22
v
Placement .........4
HydrostaticPressureTest.. .....4-5
Control
TappingsTable. ....5
BreechingErection ........6
WaterBoiler
Multiple
Zoning
With
Circulators
...
Use
WithRefrigeration
System
Bypass
Piping .
Steam
Boiler
Replacement
BoilerConnections
.
Ratings .....19
68Dimensions..... ...18-19
68VDimensions.... ......20
8-9
.9
10
10
11
12
U
68
Boiler
68V
Boiler.
IMPORTANT:
When
callingor
writing
aboutthe
boiler'
PLEASEGIVE
THE
MODEL,
SERIES,
ANDC.P.
NUM-
BER,
located
onthe boiler
nameplate.
Anyreuseor reproductionof theartwork
andcopyin
this manual
is strictly prohibited
without the written
consent
ofWeil-McLain.
DONOTUSE
PETROLEUM-BASED
CLEANING
ORSEALING
COMPOUNDS
IN BOILERSYSTEM.
SEVERE
DAMAGE
TOTHEBOILERWILLOCCUR.
-2-
v

J
Thefollowingdefinedterms
areusedthroughout
this manual
thepresence ofhazardsofvarious
risk levels,orto important
ingthelife of theproduct.
indicates presence of a hazard which
rli11cause seuere
personal injury,
death or substantial property damage
if ignored.
indicates the presenceof a hazard
rvhich coz cartse seuerepersonal in-
jury, death or substantial property
damageif ignored.
-wn-
to bring attention to
information concern-
indicates presence of a hazard which
will or can cause minor personal in-
jury or property damage if ignored.
indicates special instructions on in-
stallations, operation, or maintenance
which are important but not related to
personal injury hazards.
FAILURE TOFOLLOW
ALL INSTRUCTIONS
IN PROPER
ORDERCAN CAUSE
PERSONALINJURY OR
DEATH.READALL INSTRUCTIONS
BEFORE
INSTALLING.
J
CODES
Installations must comply with all local codes,laws, regula-
tions and ordinances.
When required, the installations must
conform to American Society of Mechanical Engineers Safety
Devices
for Automaticallv Fired Boilers. No. CSD 1.
AIRSUPPLY
FORCOMBUSTION
Adequate combustion and ventilation
air must be provided to assure proper
combustion and prevent the possibil-
ity of flue gas spillage.
Exhaust fan must not be used in
boiler area.
1.In buildings ofconventional frame, masonry or metal con-
struction, infiltration is normally adequate to provide
combustion air for boilers in unconfined rooms.
If the spaceis in a building of unusually tight construc-
tion, air should be obtained from outdoors or from spaces
which freely connect with outdoors (see
4 below).
For boilers in confined rooms, two permanent openings
shall be provided: one within 12 inches from the ceiling
and one within 12 inches from the floor ofthe room. Each
opening shall beat least one square inch per 1,000BTUH
(140 sq. in. per 1 GPH) boiler input, but must not be less
than 100 sq. inches. These openings shall freely connect
with areas having adequate infiltration from outside.
When all air is provided from outdoors the confined space
shall be provided with two openings as outlined above.
Theseopenings shall connect directly or by ducts with out-
doorsor spaces
(crawl or attic) that freely connectwith the
outdoors and shall be of the sizelisted below for that par-
ticular arrangement:
(a) Onesquare
inchper4,000BTUH(35 sq.in. per 1GPH)
ofboiler input for direct outdoor air supply through an
outside wall or through vertical ducting directly to
outside.
(b) One
squareinchper2,000BTUH (70 sq.
in.per 1
GPH)
ofboiler input for direct outdoor air through horizon-
tal ducting.
(c) All ducting shali be of the same sizeasthe opening to
which it is connected with minimum dimensions of no
Iessthan 3 x 3 inchesor 9 total square
inches
ofarea.
(d) Other sizeducting must comply with local codes.
5. For boilers installed in closets, alcoves, undercounters,
etc.,see
pages
6 and 7.
CHIMNEYOR
VENTREQUIREMENTS
DesignedforNATURAL
DRAFT
FIRINGONLY.Use
a
Class
A chimney.
Minimum chimney or vent sizes:
Boiler sizes 2
-7 - 8" x 8" square (6:11
x 63h
inside liner) or 8"
round
15feet high
Boiler sizes 8-g - 12" x 12" square (105/s
x 105/ainside liner)
or 12" round
20 feet high
In most cases a chimney or vent extended at least 3 feet above
the highest part of the roof or other structure within 30 feet
will be sufficient to prevent downdrafts. Increase chimney
cross-sectional area and height at least 4 percent for each
1.000
feetabovesea level.
Inspect existing chimney or vent be-
fore installing new boiler. Failure to
remove blockage, clean, or replace
damaged pipe can causesevere injury
or death.
An induced draft fan may be necessary if:
1) Excessive resistance to flow of combustion gases can be
expected.
2) Cross-section area of chimney is smaller than minimum
recommended.
3) Chimney height is lessthan recommended.
Ifan induced draft fan is used, overfire draft should not exceed
-.02 inches water column.
2.
4.
Section
l:Pre-lnstallation
v
-3-

-ffi-
SELECT
THEBOILER
LOCATION
CONSIDER
ALLCONNECTIONS
TO
THEBOILER
BE-
FORESELECTINGA LOCATION.
To avoid personalinjury, death or
property damage, keepboiler area
clearandfree from combustiblemate-
rials, gasolineand other flammable
vaporsandliquids.
STANDARD MINIMUM CLEARANCES
24inches-front andtop
6inches-Flue pipe
to combustible
materials.
6 inches-Right and left sides(exceptsteam with tankless
heater)
15inches-Left side
for steam
with tankless
heater.
6 inches-Back (topoutlet)
SPECIAL CLOSE CLEARANCES-See Pages6and 7.
RESIDENTIAL
GARAGE
INSTALLATION
Install boiler soburner is at Ieast18
inchesabovethe floor.
BOILERFOUNDATION
Boiler may be installed on non-carpeted combustible flooring.
Boiler legsprovide approximately one inch air spacefor natu-
ral aeration.
Boiler must be installed on level surface. If non-level condi-
tions exist or ifarea could flood,build LEVEL concreteor solid
brick foundation. See
Figure 1 and Table I.
.-FRONT OF
\\
FOUNDATION a
--7
,'M
IN
FIGURE1
2"M
lN
TABLE
I BOILER
FOUNDATIONSIZES
L = Lenothof Foundation
BoilerSize Packaqed
WaterOnly AllOtherBoilers
268 12112"
368 15112" 15112"
468 15112" 18112"
568 18112" 21112"
668 21112" 24112"
768 24112" 27112"
868 3O1lz"
968 33112"
Section
ll:Installing
Boiler
PLACEMENT
Position boiler closeto chimney. Provide minimum clearances
as indicated.
W'hen transporting with crate re-
moved, do not tip boiler forward.
Damage to burner may result.
For 8and 9-sectionblocks:
1. Tosplit block:
a. Removecleanout
plate.
b. Remove8) 5112"
tie rods.
c. Pull blockapart.Saverods,
nuts,washers,
elastomer
seals,andcopeseal.
2. Movedivided
blockto location.
3. Reassemble:
a. Clean
portopenings
with dry rag.DONOT USE OIL.
Placeelastomer
sealsin port openings.
b. Re-formcope
sealand
place
in sealing
groove.
c. Draw sectionstogether evenly until metal-to-metal
contactis madeat nipple ports.
d. Replace
cleanout
plate.
-4-
HYDROSTATIC
PRESSURETEST
Pressuretest BEFOREattachingpiping or electricalsupply
Install, but do
nothookup,tanklessheater
(ifused).
DO NOT pressure
test with water
level
control
installed.Damage
tocon-
trol canoccur.
Removeshippingnipple.
Install drainvalve.
Install valveat highesttappingtovent air.
Connectwater supply.
Plugremainingtappings.
Fill boiler.Vent all air. Testat 1Vz
timesworking pres-
surefor morethan 10minutes.
DONOTLEAVE BOILERUNAT-
TENDED.Cold
waterfill couldex-
pand
andcauseexcess
pressure.
1.
2.
3.
4.
5.
6.
u.

v
v
7. Check
for maintainedgaugepressure.
8. Check
for leaks.Repairif found.
Repair leaks at once.
Damage to boiler
can result. NEVER use petroleum-
basedstopleak compounds. Seal dam-
ageand leakage between sectionswiil
occur.
9. Drain
boilerand
remove
testing
plugs.
10. On initial start-up,
check
for leaks in system
piping. If
found.
repairatonce.
Z
LA
u-"
-a SUPPLY
rffi-
A
I
t
ri
ll
lr
WATER
HEATER
K2
SECONDARY
AIR
SHUTTER
ut
STEAM
HEATER
TABLE
II CONTROL
TAPPINGS
LOCATION SIZE WATER STEAlvl
c314" Drain Drain
D
(inplate) 1
112" High-LimitControl
(bushed
to
qa") Skim
Tapping
D
(in
water
healer)
314" Combination High-Limit
andOperating
Control
hCombination
Pressure
and
TemDerature
Gauqe Pressure
Gaugeand
PressureLimit
Control
K1 314" Water FleliefValve Gauge
Glass
and/or
Low-
WaterCuloff
(bushed
lo 112")
n2 314" Plugged Gauge
Glassand/or
Low-
Water
Cutoff
(bushed
lo
j/2")
N3t4" ToCompression
Tank Steam Relief Valve
(rn
steam
heater)
314" HeaterOperating
Control
(368through568
Boilers)
U2 314" Plugged Heater
Operating
Control
1648-q68Boilers)
f-l
tt
ll | '-(
o-l---
It
trB
i ,lj
ll
t_J_______,
vFIGURE
2
-o-

- -
JACKET
ASSEMBLY
(For
non-Packaged
boilers)
Refer to jacket erecting instructions packed in the jacket car-
ton.
BREECHING
ERECTION
Backoutlet(68)-see
Figure 3.
Topoutlet(68V)-see
Figure4.
Use
full-sized
breeching
(P-268
canbe
reducedto5inches)'
See
page
3forchimney
size.
FIGURE3
68
BREECHING
CONNECTION
Water boilers can be located in close-clearance
areas (such as
alcove.closet,under counters, etc.)
only when all instructions
in this section are followed. Substitute these instructions for
corresponding material in manual. All other procedures and
practices must remain the same.
Standard minimum clearances (shown on page 4) should be
used where possible.Where closer clearances are required:
Top of boiler-if less than 24" are available, provide remov-
able surface to allow for cleaning boiler
flueways. Distance between combustible sur-
face and boiler can be no lessthan 2 inches.
Right and/or left side-2 inches minimum.
Front of boiler-2 inches minimum from burner.
Double-wall flue pipe to combustible surface-as listed in Ta-
ble III and Figures 7 and 8 or 9.
Flue pipe clearances must take prece'
dence over jacket clearances.
Connection
mustbeabove
bottomofchimney
to avoid
block-
age.Breeching
must not enterchimneyfar enough
to cause-
of,struction.
Useathimbleorslip
joint where
breeching
enters Q
thechimney
toallowremoval
for cleaning.
Avoid longhorizontal
breechings,
ex-
cessive
numbersof elbows
or tees,or
other obstructions
restricting flow of
combustion
gases.
BAROT/i
l'Fl
.-'rrFiaFi coN-l-Ro-
' DRLL SN/AIL HOLE TO MEASURT
co2, BRttcHNC DRAtr ANU SMOKE
i
8 M:N
t
lll 56
FIGURE
4
68V
BREECHING
CONNECTION
Section
lll:Close
Clearance
Installation
1.
2.
.f.
Install boiler using clearanceslisted.
Install barometric control 18-20 inches from boiler in
breeching.
Obtain and use kit, part no. 386-500-050.
a. Attach manual reset temperature switch near upper
sudace ofenclosed area. SeeFigure 5.
b. Install switch leadsto burner primary control. SeeFig-
ure 6.
Provide two fresh air openings when installing in con-
fined space. Size each opening one square inch per 1,000
BTU (140 sq.in. per 1 GPH) input. Locate openings near
top and bottom of enclosedspace.
A
TO THE HOMEOWNER: If red
button on manual reset tempera-
ture switchhaspopped out,CALL a
YOUR SERVICEMAN IMMEDI- :
ATELY.
PITCHUP
tln"
PER
LINEAR
FOOT
,z/-!-\\
t-]
L-,
-6-

-ffi-
v
COMBUSTIBLE
SURFACE
(COUNTERTOP;
CEILING
IN
ALCOVE,
CLOSET,
r/z
PHIL.
METALSCREW
(2)
#6x
SHT
BURNER
PRIIVARY
CONTBOL
BRACKET
FIGURE5
BEMOVE
JUMPER
#10
x 1l2PHlt.
SHT.
METALSCREW
COMBUSTIBLE
SURFACE
(WALL
ORCABINET)
MANUAL
RESET
TEMP.SWITCH
DOUBLE-WALL
VfNT PIPING
NOTE:Dimension
"A"
Tablelll.
>SEE
TABLEIIIAND
FIGURE
7
- Desired
Clearance
As Shownin
FIGURE7
24"FORSERVICING
OB
MINIMU[/l
2" FOB
CLOSE
CLEARANCES
U
TO-
t\.-
FO
FO
*G ANDTNSTALLCONTROL
REFEB
TOWIRINGDIAGRAM,
PAGE15.
FIGURE6
TABLEIII PROTECTIONREQUIREDFOR
CLEARANCES
LESS
NOTES:
' All
clearances
measuredfrom
outersurfaceofequipmenttocombustible
surface,
not
tothe
protection
used.
" Applytocombustiblesurfaceunlessotherwisenoted.Coverallsurfaces
asspecifiedinTablelllandFigure7.Thicknesses
are
minimum.
"' Factoryfabricated
board
made
ofnoncombustible materials,normally
fibers,
havingthermalconductivityinrangeot1BTUinch
per
sq.ft.
per
oF
orless.
I Spacers shallbemadeofnoncombustiblematerial.
II
COMBUSTIELE
SURFACE
FIGURE8
>SEE
TABLEIIIANDFIGURE
FIGURE
9
21" f-
O?.
SiRV
C
\C OF
I'/N 2'' FCR
RT[lOVABLI
SURIACE
I TO
5INCHES
t
MANUALRESET
TEMP.
SWITCH
COMBUSTIBLE
SURFACE
PROTTCTION
THAN6INCHES'
WHENDESIREOMINIMUM
CLEARANCE
FROMDOUBLE-
WALL
VENT
PIPETO
COMBUSTIBLESURFACE
IS: USE
THE
FOLLOWINGPROTECTION''
3" 1/4 insulating millboard"
spaced out 1
"I
3" 28
gage
sheetmetalon
1/4"
insulating
millboard"'
2' 28 qaqe sheel metal spaced out 1 I
2" 28
gage
sheel
metal
on1/8"
insulating
millboard'"'spacedout1
"
I
2" 22
gage
sheetmetalon1
" mineralwool
bats
reinforced
withwireorequivalent
l/4" insulatinqmillboard'
vNOTE:2"MlN.ON
SIDES
-7-

-ffi-
Section
lV:
Piping
Connections
Failure toproperlypipe boilermayresultin improperoperation
anddamage
toboilerorbuilding.
WATERBOILER
Boiler hasbuilt-in air elimination system. A separate air elim-
inating device is not needed if expansion tank is piped as
shown.
Refer to table IV and Figures 10 and 11.
1. Sizeexpansion tank to system design requirements.
Undersized expansion tanks causesystem water to belost
from relief valve and make-up water added through fill
valve. Eventual section failure can result. Expansion
tank installation:
a) Closed type expansion tank-connect from the :]/+"
N.P.T. tapping "N" to the expansion tank using r7""
N.P.T. piping. Horizontal expansiontank piping must
pitch upward toward tank at least 1inch for each5feet
of piping.
FIGURE1O
PIPINGCONNECTIONS
FORWATERBOILERS
WITHCLOSED.TYPE
EXPANSIONTANK
b) Closeddiaphragm pre-pressurized type expansion
tank-may be
located
anywhere
inthesystem,
prefera-
bly neartheboiler.
A manual or automatictype air vent
must be installedin the 3/a" N.P.T.
tapping
"N" whenacloseddiaphragm
pre-pressurized
tank is used.
Refer
to
Figure11.
CLOSED
DIAPHRAGM
PRE-PRESSURIZED
TYPEEXPANSION
TANK=-
CIRCULATOR
FIGURE11
PIPING
CONNECTIONSFORWATERBOILERS
WITH
CLOSEDDIAPHRAGMPRE-PBESSURIZEDTANK
2. Connectsupply,return and
cold
waterfill piping.
3. Install waterreliefvalvein K1 tapping.
Relief valve discharge piping must be
piped near to the floor or to a floor
drain to eliminate potential of severe
burns. Do not pipe where freezing
could occur.
4. Iow water cutoff:
i) Should be installed if boiler is located above radiation
level.
ii) May be required on water boilers by certain state, local
or territorial codesor by insurance companies.
Use a low water cut-off designed for water installations.
An electrode probe type is recommended. Install in a tee
in supply piping above boilers.
5. If the system is to comply with ASME codes, an addi-
tional high temperature limit is needed.Purchase and in-
stall in supply piping from the boiler. t
CLOSED
TYPE
EXPANSION
TANK
TABLEIV 'WATER BOILERPIPESIZES
Boiler
Size
Supply
Pipe
Size
"4"
Return
PipeSize
"8"
Piping
to
Expansion
Tank
"C"
268t268V 1"
N.P.T 1"N.P,T 3/+" N.P.T.
368-468/368V-468V '1
1/+"
N.P.T. 11/a"N.P.T. 3/+" N.P.T.
568-768/s68V-768V 11/2"N.P.T. 11/2"N.P.T 3/a"
N.P.T.
868-968 2"N.P.T 11/2"N.P.T. 3/a"
N.P.T.
.Minimum
pipe
sizewith20oFtemperature
rise
through
theboiler
-8-

o. For multiple zoning with circulators, these changes
mustbe
made
(see
Figure 12):
a) Sizeeach
circulatortoindividualcircuitrequirements.
b) Removecirculator and preformed pipe (when fur-
nishedasstandard
equipment).
c) From1Vz'
N.P.T.
tappedreturn inlet atfront of
boiler,
construct
a pipemanifold according
to the numberof
circulatorsused.
d) Install circulators.
e) Install flow controlvalues
to preventgravity circula-
tion.
ISOLATION
VALVES-
-
ISOLATION
VALVES..
CIBCULATORS
(sEE
STEP
'b')
-ffi-
f) Install balancing
valvestoadjusttheflowso
it isabout
the same
in eachzone.
g) Separate
relays (Honeywell R845A, White-Rodgers
829A-845,or equivalent)are requiredfor eachaddi-
tional circulator.
For multiple zoning with zone valves, install balanc-
ingvalvestoadjusttheflowso
it isabout thesameineach
zone.A separatetransformer is recommendedto power
zone
valves.Referto zonevalvemanufacturer's
instruc-
tions.
t
7
MULTIPLE
ZONING
WITHCIRCULATORS
FIGURE
12
--MAY
BEINSTALLEDIN
ALTERNATELOCATIONS
FLOW
CONTROL
VALVES-'
FROMSYSTEM
U
-9 -

-wll-
USE
WITH
REFRIGERATION
SYSTEM
Theboiler
mustbe
installed
sothat chilled
medium
is
piped
in
parallel with the heating boiler with appropriate
valvesto
prevent
thechilled
mediumfromentering
theboiler.
Consult
I:B:R Installation and
PipingGuides.
f-ExPANso[]')
\I TANK )
2.To protect boiler from condensation formed by low water
temperature returned from large water content converted
gravity systems, etc., see Figure 15.
IO SYSTEM
VALVE'
-ADJUST
VALVESTOMAINTAIN
1600FORGREATERINBOILER
VALVE'
t
CIRCULATOR
STRAINER
CHECK
VALVE
SHUT.OFF
VALVE
CIRCULATOR
')
HEATING
BOILER
DK
RETURN
PIPE
FROIVCOMBINATION
HEATING&COOLING
UNITS
FIGURE
13
PIPING
FORCOMBINATION
HEATING
&
COOLING
(REFRIGERATION)SYSTEMS
BYPASSPIPING
BYPASS
PIPING IS NOT NORMALLY REQUIRED
ON
TYPICALBASEBOARD
SYSTEM.
Bypass
piping should be
usedforthe followinginstallations-
Bypass,
supply,
andreturn piping should
besame
size.
1. Toprotect
system
radiant panels,plaster,etc.
from high
temperature
watersupplied
fromboiler,
seeFigure 14.
IU
SYSTEM
FROM
SYST
CIRCULATOR
FIGURE
15
3. To protect boiler from condensation while protecting sys-
tem from high n'ater temperatures, asin large water con-
tent radiant ceiling panels,
seeFigure 16.
-ADJUST
VALVESTO
MAINTAIN160'FOR
GREATER
INBOILER
FROM
SYSTEM
12"
MAX, SYSTEM
TEMPERATURE
GAUGE
TO
SYSTEM
t
-10-
FIGURE
14
CIRCULATOR
FIGURE
16

-ffi-
STEAM
BOILER
J1.Connect piping near boiler as shown in Table V and Fig-
ures 17or 18.
Connect coldwater fill supply piping closeto boiler in the
condensate return piping.
3. Install steam reliefvalve in "N" tapping.
Relief valve discharge piping must be
piped near to floor or to a floor drain to
eliminate potential of severe burns.
Do not pipe where freezing couid oc-
cur.
RIDUCINGELBOW TO
SYSTEf,I
2.
n
CONDENSATE
RITURN
BACK
OF
BOILER
J
1I
24
MIN
)
1I
^l
l-
FIGURE
17
PIPINGCONNECTIONS
FORSIZE
3-7 STEAM
BOILERS
FIGURE
18
PIPINGCONNECTIONS
FORSIZE8-9 STEAM
BOILERS
RIDU CI
N
G
/n
CONDTNSATE
RETURN
ELEOW
TO
S
YSTtM
J
1I
24
[/lN
+
T
I
BACK
OF
BOILER
TABLEV STEAM
BOILER
PIPESIZES
Steam
Boilet
Size
Riser
PioeSize Header*
HEqualizer
J
AB
368-768 11|a"
868-968 z2112" 11Ia"
'24" minimum
from
waterlinetothebottom
ofheader
\- SHORT
NIPPTE
26 1
/8"
WAIER
LINI
SHORT
NlPPLI
26-7
/8"
WATIR
LINT
t
-11-

-wll-
REPLACEMENT
BOILER
CONNECTIONS t
ONE.PIPE
STEAM
SYSTEM
Recommendedpiping for replacement boiler on older one-pipe
steam system is shown below.
Someinstallations may require an addedwater tank for addi-
tional steaming capacity. By installing two plugged tees as
shown in Figure 19, a tank can easily be added ifnecessary.
Obtain Bulletin AE 8403 from your Weil-Mclain distributor
for tank sizing.
HEADER
AND
SUPPLY
RISERS
SAMESIZE
ASOLDSYSTEM
-OR PERASHRAE
RECOMMENDATIONS
4REDUCING
ELL
PIPINGTO
OPTIONAL
RESERVOIRTANK
NORMALLY
NOTE:
SWING
JOINTS
NOTSHOWN
REDUCING
ELL
FIGURE19
RECOMMENDED
PIPINGFORREPLACEMENT
STEAMBOILER_ONE-PIPE
SYSTEM
t
\,r7
\
t
q-
--
/
PLUGGEI
tl
-L2-

Effi-
tSection
V:Tankless&Storage
Heater
Hook-up
TANKLESSHEATER
HOOK.UP
Install as shownin Figure 20 (waterboiler)
or Figure 21
(steam
boiler).2681268Vcannotuseatanklessheater.
1. Install automaticmixing valve.
2. Install flow regulatingvalve.
Sizeaccordingto intermit-
tent drawofheaterasshownin TableVI.
3. Operatingcontrolwith a smalldifferentialscale is
recom-
mended.Install in temperature
controltappingin heater
plate.
4. In hardwaterareas, it isadvisabletosoftencold
domestic
supply
water
totanklessheaterto
prevent
lime
build-up.
OUTLET
MIN,
HEATER MIXED
_t
FIGURE20
TANKLESSHEATER
PIPING
(WATER
BOILER)
:/a"
TEMPERATURE
TAPPING
TABLE
VI STEAM ANDFORCEDHOT
WATER
BOILERTANKLESSHEATER
RATINGS
Werl-McLain
ratings
basedon60
PSIG
domeslic
water
pressure
at
heater.
' GallonsolwaterDerminute
heatedlrom40o
lo 140oF.wilh200"F boilerwater
IemperaIUre.
" Continuous draw-no recovery period I Not avarlableon 268/268V boilers
STORAGEHEATERHOOK.UP
(forced
hotwater
boileronly)
62-2-EStorageHeatercannotbeused
with 268i268V
thru 568/568V
forced
hot water boilers or any size steam
boiler.
Locate tank ashigh as possible above boiler.
Vertical type storage tank can be used ifbottom oftank
can be located above top ofboiler.
3. To provide gravity circulation:
a) Horizontal supply from heater to tank must pitch up-
ward 1 inch for each 10feet ofpiping.
b) Horizontal return from tank to heater must pitch
downward 1 inch for each 10 feet of piping.
4. Locate return piping above storage heater.
5. Use asfew elbows and pipe fittings aspossible
'No.62-2-Estorageheatercannotbeusedwith268/268V
through
568/568Vwater
boilersor
withanysteamboilers.
Boilerl
Size Heater No.
'lntermlttent
DrawGPM
1
00oF.
Average
Temp.Rlse
"Continuous
DrawGPM
100.F
Temp.
Rise
lnlet
and
Outlet
Taooinos
Temp.
Control
Taooino
WATER
368/368V
468/468V
568/568V
668/668V
768t764V
868-968
E-624
E-624
E-624
E-626
E-632
E-632
3.00
3.25
3.25
3.50
4.25
4.50
2.O0
2.70
3.30
4.00
4.60
4.75
112"
112"
112"
112"
112"
112"
sl4"
314"
E4"
314"
34"
STEAM
368
468
568
668
768-968
35-S.29
35-S-29
35-S29
35,S
29
3s-s-29
3.00
3.25
3.50
375
4.00
2.OO
2.70
3.30
4.00
4.60
g4
314
314
314
314
314"
314'
314'
84"
314"
FLOW coLD
FEGULATING
WATER
VALVE SUPPLY
BRASS
ELBOW
INLE\
CONTROL
+JACKET
. FFONT
,"o., ---I-I
IEE
I
I xor
t-
1.
2.
t
I
I
COLD
WATER
SUPPLY
AUTOMATIC
MIXING
VALVE
PREssUAE TEMPER^TURE
,i;* L lnt A
E +}l_ ,,
!'1- 'F^'t
{re
tFIGURE21
TANKLESS
HEATER
PIPING
(STEAM
BOTLER)
COLD
TABLE
VII STORAGEHEATERRATINGS
BoilerSize'
Storage
Heater
Number
180o Boiler Water
Healer Capaclty
Gallons
40o-1 40o Rise
212' BoilerWater
Hester
Capacily
Gallons
400-140" Rlse
668 968
668V-768V 62-2-E 50in3 Hours 70in
3Hours
Recommended
Storaqe
Tank 50-90Gallons 75-125
Gallons
F_
\ OP€RAI NC
r 'gl!9!
n
;iru?. {t
COLD
-13-

-ffi-
A
For
1
Failure to properly install, pipe and
wire boiler controls may result in se-
vere damage to boiler, building and
personnel.
WATER
BOILER
CONTROLS
1. Install control where shown on tapping table, page 5.
1.
STEAM
BOILERCONTROLS
Connect a low water cut-off to gauge glass tappings Kl
and K2. Refer to Figure 23. Follow instructions packed
with control. Pipe drain near the floor or floor drain.
Install the pigtail syphon, pressure gauge and steam pres-
sure limit control' SeeFigure 23'
OIL
BURNER
For B-68/68Vboiler:
1. Place
gasket
over
endofair tube.
2. Looselyscrew
threemountingboltsintoboilermounting
plate.
*x s rurppue
' (aRess)
jree (aness)
jrt NIPPLE
(BRAss)
STEAMGAUGE
olxrjNreer-E
FoR
HIGH
LIMIT
PRESSURE
CONTROL
Mount burner.
Tighten mounting bolts.
A-68/68V boiler:
Secure universal mounting flange and gasket to burner
mounting plate. Use three bolts provided.
Position burner so it is level to 1112"
tilt downward' Air
tube should beflush to 1/a
inch recessed
from inside wall of
combustion chamber.
;fstneer
euu
*xgtttPPue
--
'(ennss)
f srneer
jree
ELL
e{,
LOWWATER
CUT.OFF
*67WP
FIGURE23
STEAM
CONTROLS
Section
Vll:
Wiring&Fuel
Line
Piping
WIRING
For your safety, turn off electrical
power supply at service entrance
panel before making any electrical
connections to avoid possible electri-
cal shock hazard.
Wiring must comply
with the National Electrical Codeand
anyadditionalnational,state,orlocalcodes.
Seewiring diagram,
page
15forproper
wiring.
-14-
All safetycircuit
wiring mustbeN.E.C.
Class
1.
Foranyadditional
electrical
safety
controls,use
No.14gatge
wire. Electricalsupply
wiring to burner shouldbe No. 14
gauge
orheavier
with fuseddisconnect
switch.
Besureboiler
isproperly
grounded
at switchbox.
FUELLINE
PIPING
Refer
to separate
burner
manualandanylocal
or national t/
coderequirements which may apply to sizing and installing
the fuel line piping.
Section
Vl:
Non-packaged
Boilers-Control
&
Burner
Installation

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)
)
,

-ffi-
Section
Vlll:
Final
Adjustments
WATER TREATMENT
Never use petroleum based stop-leak compounds. Water
sealdeterioration will occur,resulting in leakage between sec-
tions.
Continual make-up water will reduce boiler life. Minerals can
buiid up in the sections, reducing heat transfer, overheating
the cast iron, and causing section failure.
For unusually hard water areas or low pH conditions (less
than 7.0)consult local water treatment company.
Freeze protection (when used):
Use antifreeze especially made for hydronic systems. Inhib-
ited propylene glycol is recommended. DO NOT useundiluted
or automotive type antifreeze.
507osolution provides maximum protection to about - 30'F.
Local codes
may require a back-flow preventer or actual dis-
connect from city water supply.
Determine quantity according to system water content. Boiler
water content is listed on page 18.
Follow antifreeze manufacturer's instructions.
FILLING
WATER
BOILER
1. Close manual air vents, drain cocks, and automatic air
vent, if used.
BURNER
ADJUSTMENT
Final burner adjustments
must be
madeusing combustion
test equip-
ment to assure
properoperation.
DO
NOT FIRE BOILER WITHOUT WA.
TER OR SECTIONS
WILL OVER.
HEAT.
Refer to burner manual for start-up. Adjust air band to
provide a clean yellow flame without smokey tips.
Allow boilers to heat to design conditions.
Using combustion test equipment, adjust burner for:
a) 0 smoke
with maximum COr.
b) - 0.02 inches W.C. negative draft overfire.
SKIMMING
STEAM
BOILER
Clean newly installed steam boiler to
remove oil and grease.Failure to prop-
erly clean can result in violent fluctua-
tions ofwater level, water passing into
steam mains, or high maintenance
costson strainers, traps and vents. Do
Z.
2.
t).
4.
Fill to correct system pressure. Correct pressure will vary
with each application.
Open automatic air vent two turns, if used.
a) Starting on lowest floor, open air vents one at a time
until water squirts out. Close vent.
b) Repeat with remaining vents.
Refill to correct pressure.
Close,then open automatic air vent, if used, one full turn
for normal boiler operation.
6.
FILLINGSTEAM
BOILER
1. Do not fill (except
for leakage tests)until boiler is ready to
be fired.
2. Fill to normal waterline, halfway up gauge glass.
3. Boiler water pH 7.0 to 8.5 is recommended.
4. Follow skimming procedure.
il?JJ." petroleum
based
producttt" G
1. Provide 11/2"
piping from boiler skim tapping to floor
drain.
2. Adjust waterline to midpoint of skim piping.
3. Fire boiler to maintain a temperature below steaming
rate during skimming process.
4. Feed in water to maintain water level. Cycle burner to
maintain temperature below steaming.
5. Continue skimming until discharge is clear. This may
take severalhours.
6. Drain boiler. While boiler is warm but NOT HOT, flush
all interior surfacesunder full pressure until drain water
runs clear.
7. Remove
skim piping and plug tapping.
8. Close
drain cock.Fill with fresh water to waterline. Start
burner and steam for 15 rninutes to remove dissolved
gases.
Stop
burner.
9. Check traps and air vents for proper operation.
-16-

)
-ffi-
Section
lX:
Check-out
Procedure
n
u2
'a
I'- A
L] D.
CHECK.OUT
PROCEDURE
(Check-off
steps
ascompleted.)
Water boiler:
a. System properly filled with water?
b. Air purged from system?
c. Automatic air vent, if used, open oneturn?
Steamboiler:
ii. Boiler properly filled rvith rvater?
b. Svstem vents operating properly'?
c. Boiler properly skimmed?
Air purged lrom oil piping? Piping checkedfor leaks?
Proper draft and burner flame? Final adjustment
made with combustion test equipment?
Test safety controls: If boiler is equipped with a low
water cut-off or additional safety controls, test for op-
eration as outlined by manufacturer. Burner should
be operating and should go off when controls are
tested. When safety devices are restored, burner
shouldreignite.
6. Test ]imit control: While burner is operating, move in-
dicator of limit control below actual boiler water tem-
perature or pressure. Burner should go off. Circulator
should continue to operate (water boilers only). Raise
limit control above boiler water temperature or pres-
sure and burner should reignite.
7. Limit control setto design temperature or pressure re-
quirements of system? Maximum limit setting
-240'F. (water boilers)-15 psi (steam
boilers).
8. For n"rultiplezones,flow adjusted so it is about the
samein each zone
(water boilersonly)?
9. Thermostat heat anticipator set properly? Refer to
wiring diagram.
10. Boiler cycled with thermostat? Raise to highest set-
ting. Boiler shouid go through normal start-up cycle.
Lower to lowest setting. Boiler should go off.
11. Several operating cycles observed for proper opera-
tion?
12. Room thermostat set to desired temperature?
13. All instructions shipped with boiler reviewed with
owner or maintenance person, returned to envelope
and given to owner or displayed near boiler?
14. On initial start-up,
check
for leaksin system
piping. If
found. renair at once.
tl
tl
LI
LJ
L]
t_
Installation
andServiceCertificate
BOILERMODEL SERIES CP
NUMBER DATEINSTALLED
Ll Installation
instructions
have
been
followed.
E Check-out
sequence
hasbeen
performed.
I Abou"informationiscertiliedtobecorrect.
n lnformation received
and
left
withowner/maintenanceoerson
BTUINPUT
lnstaller(Company) (Address) (Phone)
-17-
(l
nstaller's
Signature)

- [HIl
-
r}
@,
t Basedonstandard
test
proceduresprescribed
by
theUnitedStates
DeparlmentofEnergy
atcombustion
conditionof130/oCOz
ratingsarebaiedona
piping
and
pick-up
allowanceol
1.15.Steam
ratingsarebasedon
anallowance
of1
.333.Anadditional
allowanceshould
bemade
forunusual
piping
and
pick-up
loads.
I IBRGrossOutput
68
REAR
FLUEOUTLET
RETURN
SKIM
TAPPING
PACKAGED
FRONT
(STEAM)
^3
,iL
PACKAGED
FRoNr (wArER) |
^Z
TCONDARY
IRTTER
,l'
rl
-trr I
I--
Z
-ft
SUPPLY
-t
D
WATER
LIN
E
loE
f 15"
minimum
heater
clearance
RETURN
t ll
WATER_-+
,ll I
'4 1
Section
X:Ratings-Data
BOITER I=B=B
BURNERCAPACITY
GPH
iDOEHEATING
CAPACITY
MBH NETI=B=B
RATINGS- l=8=RCHIMNEY EOILERWATER
CONTENT
(GAt.)
STTAM
s0.
FT. STEAM
MSlt WATEB
MBH SIZE
INCHES HEIGHT
FEET WATER
P6St''qprB-63l/
TA rt B{S STEAM
(To
Walerline)
PREFIX NUMBER STEAM WATER
P268t268V o.70 oo 74.8 8x8 15 7.O
A,8,
f
368
368V 0.95
0.9s 113 14
14
JC3 84.8 99.1
99.1 8x8
8x8 15
15 13.3
IJ.J
3.3
3.3 11.2
A,B,
P468
468V 1.25
1.25 149 51
51 a: 111.8 31.3 8x8
8x8
't5
l5
8.6
8.6 4.9
4.9 12.4
A,B,
r568
568V 1.50
1.50 179 181
.t
8l ':' 134.3 157.4
157.4 8x8
8x8
'15
15 10.2
't0.2 6.5
6.5 13.6
A,B,
P668 668V 1.80
1.80 216 218
218 675 162.0 189.6
189.6 8x8 8x8 5
51.8
1.8 8.1
8.1 14.8
A,B,
P/od
768V 2.05
2.05 246 ?48
248 770 184.5 215.7
215.7 8x8
8x8 5
53.4
3.4 9.7
9.7 to. I
A,B 868 230 2691 2691 840 201.8 233.9 12 20 zt.J 17.4
A,B 968 2.55 298t 2981 930 223.6 259.1 12 20 22.9 18.6
BOILER
slzE A
flN) B flN)
L'flN)
PACKAGED
WATER
PACKAGEDSTEAM
f,R
KNOCKED
OOWN
WATERORSTEAM
268 9tlz 1
0s/e
368 91lz 33/g 13c/e
468 12112 13s/e 169/s
s68 15112 63/s 19:/e
oob 18112 19s/e 22sle
768 21112 22sla 25qe
868 25tla 24112 28slB
968 28114 27tlz 31:/a
'Jacket extension increases length 17112in
-18-
ASSEMBLED
FRONT .lto
ll

)
68
REAR
FLUEOUTLET
(Continued)
-ffi-
PACKAGED
srDE
(STEAM)
INTERMEDIATE
-19-
HEATER
-
LOCATION
PACKAGED
srDE
(WATER)
ul
STE
AM
HEATER
ASSEMBLED
LEFT
SIDE
20 -l
r6i 1.
.1 F-OR
7,,
VENT
PIPE
2"
RETURN
STEAM
1__
!,r T-
r6-
BACK

-wfl-
RETURN
PACKAGED
FRONT
(WATER
ONLY)
t*
to
4-?=
lr'"
42+
t-
I
ASSEMBLED
LEFTSIDE
-20-
68V
TOP
FLUEOUTLET
+268Vavailableas
packaged
unitonly
.Jacket
extension
increaseslength
.l
7112in
a
WATER
HEATER
SECONDARY
AIR
SHUTTER a)'owrN
FRoNr
. PLATE
,t'
RETURN
r- -{-
c3J I
'4 I
-1
PACKAGED
SIDE
(WATER
ONLY)
--1Al*vENrP|PE
ll,
-L
BACK
BOILER
SIZE INCHES
ABEL'
268V+ 591lz 5s/r
e103/8
368V 59tlz 5e/r
sl3gie
468V 612112 I tt16 133/g
568V ol5tlz I tt16 16s/e
668V 718tlz T II16 19s/a
768V 72ltlz Ttlta 22sla
-{F
t-
l-
l.1=,i
at_;
'
il
i'.1
t_J_-______, ,sf
l;-
INTERMEDIATE !