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UEll'flhHlil 68 and68V oil-FiredBoilerManual lncludes: . Installation o Start-up . Service o Parts - 68 BOILER REARFLUEOUTLET 68V BOILER TOP FLUEOUTLET J Any claims for damage or shortage in shipment must be filed immediatelyagainst the transportationcompany by the consignee. Part No. 550-110-49410487WP -ffiTableof Contentsv Air Supplyfor Combustion. . . . Chimneyor Vent Requirements S t a n d a r dM i n i m u mC l e a r a n c e s BoilerFoundaton Placement HydrostaticPressureTest.. C o n t r oTl a p p i n g s T a b l e . BreechingErection WaterBoiler MultipleZoningWith Circulators. . . System Use With Refrigeration BypassPiping . SteamBoiler ReplacementBoilerConnections. J WiringDiagram '.'.15 4 4 .........4 .....4-5 ....5 ........6 8-9 .9 10 10 11 12 WaterTreatment... FreezeProtection FillingWaterBoilers FillingSteamBoilers BurnerAdjustment S k i m m i nSg t e a mB o i l e r s. . . . ......16 16 .......16 ......16 ........16 ..... 16 Check-OutList... lnstallationandServiceCertificate ........17 ....... 17 Ratings 68Dimensions..... 68VDimensions.... .....19 ...18-19 ......20 68 Boiler 6 8 VB o i l e r . Whencallingor writingaboutthe boiler' IMPORTANT: PLEASEGIVETHE MODEL,SERIES,AND C.P. NUMBER, located on the boiler nameplate. 21 22 Any reuse or reproduction of the artwork and copy in this manual is strictly prohibited without the written consentof Weil-McLain. DO NOT USE PETROLEUM-BASEDCLEANINGOR SEALINGCOMPOUNDSIN BOILERSYSTEM. SEVEREDAMAGETO THE BOILERWILL OCCUR. -2- U v -wnThe following definedterms are usedthroughout this manual to bring attention to the presenceof hazardsof various risk levels,or to important information concerning the life of the product. J indicates presence of a hazard which will or can cause minor personal injury or property damage if ignored. indicates presence of a hazard which rli11 cause seuere personal injury, death or substantial property damage if ignored. indicates special instructions on installations, operation, or maintenance which are important but not related to personal injury hazards. indicates the presence of a hazard rvhich coz cartse seuere personal injury, death or substantial property damage if ignored. FAILURE TO FOLLOW ALL INSTRUCTIONSIN PROPERORDER CAN CAUSE PERSONAL INJURY OR DEATH. READ ALL INSTRUCTIONSBEFORE INSTALLING. l: Pre-lnstallation Section CODES J Installations must comply with all local codes,laws, regulations and ordinances. When required, the installations must conform to American Society of Mechanical Engineers Safety Devices for Automaticallv Fired Boilers. No. CSD 1. AIR SUPPLYFORCOMBUSTION Adequate combustion and ventilation air must be provided to assure proper combustion and prevent the possibility of flue gas spillage. Exhaust fan must not be used in boiler area. 1 . In buildings of conventional frame, masonry or metal construction, infiltration is normally adequate to provide combustion air for boilers in unconfined rooms. 2 . If the space is in a building of unusually tight construction, 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 of the room. Each opening shall be at least one square inch per 1,000 BTUH (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. v 4 . When all air is provided from outdoors the confined space shall be provided with two openings as outlined above. These openings shall connect directly or by ducts with outdoors or spaces(crawl or attic) that freely connect with the outdoors and shall be of the size listed below for that particular arrangement: (a) One square inchper4,000BTUH(35 sq. in. per 1 GPH) ofboiler input for direct outdoor air supply through an outside wall or through vertical ducting directly to outside. (b) One square inch per 2,000 BTUH (70 sq. in. per 1 GPH) ofboiler input for direct outdoor air through horizontal ducting. (c) All ducting shali be of the same size as the opening to which it is connected with minimum dimensions of no Iessthan 3 x 3 inches or 9 total square inches ofarea. (d) Other size ducting must comply with local codes. 5. For boilers installed in closets, alcoves, undercounters, etc., see pages 6 and 7. CHIMNEYOR VENTREQUIREMENTS Designed for NATURALDRAFTFIRINGONLY.Usea Class A chimney. Minimum chimney or vent sizes: Boiler sizes 2 -7 - 8" x 8" square (6:11x 63h inside liner) or 8" round 15 feet high Boiler sizes 8-g - 12" x 12" square (105/sx 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 feet above sea level. Inspect existing chimney or vent before installing new boiler. Failure to remove blockage, clean, or replace damaged pipe can cause severe 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 less than recommended. Ifan induced draft fan is used, overfire draft should not exceed -.02 inches water column. -3- -ffi.-FRONT OF \\ FOUNDATION SELECTTHEBOILERLOCATION TO THE BOILERBEALL CONNECTIONS CONSIDER FORE SELECTING A LOCATION. --7 To avoid personal injury, death or property damage, keep boiler area clear and free from combustible materials, gasoline and other flammable vapors and liquids. ,'M IN STANDARD MINIMUM CLEARANCES 24 inches-front and top 6 inches-Flue pipe to combustiblematerials. 6 inches-Right and left sides (except steam with tankless heater) 15 inches-Left side for steam with tankless heater. 6 inches-Back (top outlet) SPECIAL CLOSE CLEARANCES-See Pages 6and 7. RESIDENTIALGARAGEINSTALLATION Install boiler so burner is at Ieast 18 inches above the floor. BOILER FOUNDATION Boiler may be installed on non-carpeted combustible flooring. Boiler legs provide approximately one inch air space for natural aeration. Boiler must be installed on level surface. If non-level conditions exist or ifarea could flood, build LEVEL concrete or solid brick foundation. See Figure 1 and Table I. a 2"M lN F I G U R E1 BOILERFOUNDATIONSIZES TABLE I L = Lenoth of Foundation All Other Boilers PackaqedWater Only Boiler Size 268 12112" 368 468 568 668 768 15112" 15112" 15112" 18112" 18112" 21112" 21112" 24112" 24112" 27112" 3O1lz" 868 968 33112" Boiler ll: Installing Section PLACEMENT Position boiler close to chimney. Provide minimum clearances as indicated. W'hen transporting with crate removed, do not tip boiler forward. Damage to burner may result. For 8 and 9-section blocks: 1. To split block: a. Removecleanout plate. b. Remove8) 5112"tie rods. c. Pull block apart. Save rods, nuts, washers,elastomer seals,and copeseal. 2. Move divided block to location. 3. Reassemble: a. Clean port openingswith dry rag. DO NOT USE OIL. Placeelastomersealsin port openings. b. Re-formcopeseal and place in sealing groove. c. Draw sections together evenly until metal-to-metal contact is made at nipple ports. d. Replacecleanout plate. -4- PRESSURE TEST HYDROSTATIC Pressuretest BEFORE attaching piping or electrical supply Install, but do not hook up, tankless heater (ifused). DO NOT pressure test with water level control installed. Damageto control can occur. 1 . Removeshipping nipple. 2 . Install drain valve. 3 . Install valve at highest tapping to vent air. 4 . Connect water supply. 5 . Plug remaining tappings. 6 . Fill boiler. Vent all air. Test at 1Vztimes working pressure for more than 10 minutes. DO NOT LEAVE BOILER UNATTENDED.Cold water fill couldexpandand causeexcesspressure. u. rffiv TABLE II CONTROLTAPPINGS 7. Check for maintained gaugepressure. 8. Check for leaks. Repair if found. c Repair leaks at once. Damage to boiler can result. NEVER use petroleumbased stop leak compounds. Seal damage and leakage between sections wiil occur. 9. Drain boiler and removetesting plugs. 10. On initial start-up, check for leaks in system piping. If found.repair at once. STEAlvl WATER LOCATION SIZE 314" Drain Drain D (in plate) 1 112" High-LimitControl (bushedto qa") SkimTapping D (in water 314" CombinationHigh-Limit and OperatingControl healer) h CombinationPressure Gauqe and TemDerature PressureGaugeand PressureLimitControl K1 314" Water Flelief Valve GaugeGlassand/orLowWaterCuloff(bushed lo 112") n2 314" Plugged GaugeGlassand/orLowWaterCutoff(bushed lo j/2") 3t4" To CompressionTank Steam Relief Valve N HeaterOperatingControl (368through568 Boilers) 314" (rnsteam heater) U2 314" HeaterOperatingControl 1648-q68Boilers) Plugged A v I tri Z LA u-" -a SUPPLY ll lr WATER HEATER K2 f-l tt ut ll STEAM HEATER SECONDARY AIR SHUTTER | '-( o-l--- It trB ,lj i ll t _ J _ _ __ _ _ _ , F I G U R E2 v -o- - - JACKETASSEMBLY boilers) (Fornon-Packaged Refer to jacket erecting instructions packed in the jacket carton. Connectionmust be abovebottom of chimney to avoid blockage. Breeching must not enter chimney far enough to cause of,struction.Use a thimble or slip joint wherebreechingenters Q the chimney to allow removal for cleaning. Avoid long horizontal breechings,excessivenumbers of elbows or tees, or other obstructionsrestricting flow of combustiongases. B R E E C H I N GE R E C T I O N (68)-see Figure 3. Back outlet Top outlet (68V)-see Figure 4. Use full-sizedbreeching(P-268can be reducedto 5 inches)'See page3 for chimneysize. P I T C HU P tln" PER LINEARFOOT B A R O T / il ' F l. - ' r r F i a F i c o N - l - R o - ,z/-!-\\ t-] L-, i ' DR LL SN/AIL HOLE TO MEASURT co2, BRttcHNC DRAtr ANU SMOKE M:N 8 t lll 56 F I G U R E4 CONNECTION 68V BREECHING F I G U R E3 68 BREECHINGCONNECTION Installation Clearance lll:Close Section 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. 1 . Install boiler using clearances listed. 2 . Install barometric control 18-20 inches from boiler in breeching. .f. Standard minimum clearances (shown on page 4) should be used where possible. Where closer clearances are required: less than 24" are available, provide removable surface to allow for cleaning boiler flueways. Distance between combustible surface and boiler can be no less than 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 Table III and Figures 7 and 8 or 9. Top of boiler-if Flue pipe clearances must take prece' dence over jacket clearances. -6- A Obtain and use kit, part no. 386-500-050. a. Attach manual reset temperature switch near upper sudace ofenclosed area. See Figure 5. b. Install switch leads to burner primary control. See Figure 6. Provide two fresh air openings when installing in confined 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 enclosed space. TO THE HOMEOWNER: If red button on manual reset temperature switch has poppedout, CALL a YOUR SERVICEMAN IMMEDI- : ATELY. COMBUSTIBLE SURFACE (COUNTERTOP; C E I L I N GI N ALCOVE,CLOSET, -ffiC O M B U S T I B LS EU R F A C E v # 6 x r / zP H I L . S H T METALSCREW(2) I TO5 INCHES t PROTTCTION M A N U A LR E S E T T E M P .S W I T C H #10 x 1l2PHlt. S H T .M E T A LS C R E W COMBUSTIBLE SURFACE ( W A L LO R C A B I N E T ) BRACKET DOUBLE-WALL VfNT PIPING N O T E : D i m e n s i o n" A " - DesiredClearanceAs Shown in T a b l el l l . F I G U R E5 F I G U R E7 BURNER PRIIVARY CONTBOL MANUAL RESET T E M P .S W I T C H TOt\.- 2 4 " F O RS E R V I C I N G O B M I N I M U [ /2l " F O B C L O S EC L E A R A N C E S FO FO U *G B E M O V EJ U M P E R ANDTNSTALLCONTROL R E F E BT O W I R I N GD I A G R A MP, A G E1 5 . I F I G U R E6 I COMBUSTIELE SURFACE TABLEIII PROTECTION REQUIRED FORCLEARANCES LESS T H A N6 I N C H E S ' WHENDESIREOMINIMUM CLEARANCEFROMDOUBLEWALL VENT PIPETO COMBUSTIBLESURFACEIS: > S E E T A B L EI I I A N DF I G U R E7 F I G U R E8 USETHE 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 metalon 1/8"insulating m i l l b o a r d ' " 's p a c e do u t 1" I 2" 22 gage sheetmetalon 1" mineralwool bats reinforcedwith wireor equivalent 2 1 " f -O ? . SiRVC \C OF I'/ N 2'' FCR RT[lOVABLI SURIACE l / 4 " i n s u l a t i n qm i l l b o a r d ' v NOTES: ' All clearancesmeasuredfrom outersurfaceof equipmentto combustible surface,not to the protectionused. " Applyto combustiblesurfaceunlessotherwisenoted.Coverall surfaces a s s p e c i f i e di n T a b l el l l a n d F i g u r e7 . T h i c k n e s s easr e m i n i m u m . "' Factoryfabricatedboardmade of noncombustible materials,normally fibersh , a v i n gt h e r m acl o n d u c t i v i tiyn r a n g eo t 1 B T U i n c hp e r s q . f t . p e r o F or less. I material. Spacersshall be madeof noncombustible > S E E T A B L EI I I A N DF I G U R E N O T E : 2 " M l N .O N S I D E S F I G U R E9 -7- -ffi- lV:Piping Connections Section Failure to properly pipe boiler may result in improper operation and damageto boiler or building. WATERBOILER Boiler has built-in air elimination system. A separate air eliminating device is not needed if expansion tank is piped as shown. Refer to table IV and Figures 10 and 11. 1. Size expansion tank to system design requirements. Undersized expansion tanks cause system water to be lost from relief valve and make-up water added through fill valve. Eventual section failure can result. Expansion tank installation: from the :]/+" a) Closed type expansion tank-connect N.P.T. tapping "N" to the expansion tank using r7"" N.P.T. piping. Horizontal expansion tank piping must pitch upward toward tank at least 1 inch for each 5 feet of piping. C L O S E DT Y P E TANK EXPANSION C L O S E DD I A P H R A G M PRE-PRESSURIZED T Y P EE X P A N S I O N TANK=- CIRCULATOR F I G U R E1 1 P I P I N GC O N N E C T I O NFSO RW A T E RB O I L E R S W I T HC L O S E DD I A P H R A G M PRE-PBESSURIZE TD ANK TABLE IV Boiler Size 268t268V 368-468/368V-468V 568-768/s68V-768V 868-968 'WATER BOILERPIPESIZES 1"N.P.T 1"N.P,T Piping to Expansion Tank"C" 3 / + "N . P . T . ' 11 / + " N.P.T. 1 1 / a "N . P . T . 3 / + "N . P . T . 1 1 / 2 "N . P . T . 1 1 / 2 "N . P . T 3 / a "N . P . T . Supply Pipe Size "4" Return Pipe Size "8" 3 / a "N . P . T . . M i n i m u mp i p es i z ew i t h2 0 o Ft e m p e r a t u rrei s et h r o u g ht h e b o i l e r 2" N.P.T 11/2N " .P.T. 2. Connectsupply, return and cold water fill piping. 3. Install water relief valve in K1 tapping. F I G U R E1 O FORWATERBOILERS PIPINGCONNECTIONS WITH CLOSED.TYPEEXPANSIONTANK b) Closed diaphragm pre-pressurizedtype expansion tank-may be locatedanywherein the system,preferably near the boiler. A manual or automatic type air vent must be installed in the 3/a" N.P.T. tapping "N" when a closeddiaphragm pre-pressurizedtank is used.Refer to Figure 11. -8- 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 codes or 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 additional high temperature limit is needed. Purchase and install in supply piping from the boiler. t -ffio. t For multiple zoning with circulators, these changes must be made (seeFigure 12): a) Sizeeachcirculator to individual circuit requirements. b) Remove circulator and preformed pipe (when furnished as standard equipment). c) From 1Vz' N.P.T. tappedreturn inlet at front of boiler, construct a pipe manifold accordingto the number of circulators used. d) Install circulators. e) Install flow control values to prevent gravity circulation. f) Install balancingvalvesto adjust the flow soit is about the same in eachzone. g) Separate relays (Honeywell R845A, White-Rodgers 829A-845,or equivalent) are required for each additional circulator. 7 For multiple zoning with zone valves, install balancing valvesto adjustthe flow soit is aboutthe samein each zone. A separatetransformer is recommendedto power zonevalves. Refer to zonevalve manufacturer's instructions. ISOLATIONVALVES-- FLOWCONTROL VALVES-' FROMSYSTEM ISOLATION VALVES.. - -MAYBE INSTALLED IN CIBCULATORS ( s E E S T E P' b ' ) ALTERNATELOCATIONS MULTIPLEZONINGWITH CIRCULATORS F I G U R E1 2 U -9 - -wllSYSTEM USEWITHREFRIGERATION The boiler must be installed sothat chilled medium is piped in parallel with the heating boiler with appropriate valves to prevent the chilled medium from entering the boiler. Consult I:B:R Installation and Piping Guides. 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. ) t IO SYSTEM CIRCULATOR VALVE' SHUT.OFF VALVE - A D J U S TV A L V E ST O M A I N T A I N 1 6 0 0 FO R G R E A T E RI N B O I L E R VALVE' ') STRAINER C H E C KV A L V E HEATING BOILER DK CIRCULATOR R E T U R NP I P E F R O I VC O M B I N A T I O N H E A T I N G& C O O L I N GU N I T S F I G U R E1 3 P I P I N GF O RC O M B I N A T I O N NY) S T E M S H E A T I N G& C O O L I N G( R E F R I G E R A T I OS F I G U R E1 5 BYPASS PIPING BYPASS PIPING IS NOT NORMALLY REQUIRED ON TYPICAL BASEBOARDSYSTEM. Bypasspiping should be usedfor the following installationsBypass,supply, and return piping should be same size. 3. To protect boiler from condensation while protecting system from high n'ater temperatures, as in large water content radiant ceiling panels, see Figure 16. 1. To protect system radiant panels,plaster, etc. from high temperature water suppliedfrom boiler, seeFigure 14. IU SYSTEM - A D J U S TV A L V E ST O M A I N T A I N1 6 0 ' F O R G R E A T E RI N B O I L E R FROM SYSTEM 12" MAX, SYSTEM T E M P E R A T U RG EAUGE TO SYSTEM FROM SYST CIRCULATOR CIRCULATOR t F I G U R E1 4 -10- F I G U R E1 6 -ffiSTEAMBOILER J 1 . Connect piping near boiler as shown in Table V and Fig- TABLE V STEAMBOILERPIPESIZES ures 17 or 18. Riser Pioe Size Header* SteamBoilet H B A Size 368-768 2112" z 868-968 '24" minimumfromwaterlineto the bottomof header 2 . Connect cold water fill supply piping close to 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 occur. R I D U C I N GE L B O W n TO SYSTEf,I J 1I F I G U R E1 7 P I P I N GC O N N E C T I O N S FORSIZE 3-7 STEAMBOILERS 24 MIN 26 1/8" WAIER L I NI ) ^l l- 1I \- CONDENSATE RITURN SHORT NIPPTE BACK OF BOILER RIDU CING E L E O W /n TO SYSTtM J 1I 24 [/ lN + F I G U R E1 8 P I P I N GC O N N E C T I O N S FORSIZE 8-9 STEAMBOILERS t T I CONDTNSATE RETURN 26-7 /8" WATIR L I NT SHORT NlPPLI BACK OF BOILER -11- Equalizer J 11|a" 11Ia" -wllCONNECTIONS BOILER REPLACEMENT STEAMSYSTEM ONE.PIPE t Recommended piping for replacement boiler on older one-pipe steam system is shown below. Some installations may require an added water tank for additional 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 for tank sizing. distributor H E A D E RA N D S U P P L YR I S E R S SAME SIZEAS OLD SYSTEM - O R P E RA S H R A E RECOMMENDATIONS R E D U C I N GE L L 4 ELL REDUCING t \,r 7 P I P I N GT O O P T I O N A L RESERVOIR TANK q- -- \ t / N O R M A L L YP L U G G E I NOTE: NOTSHOWN JOINTS SWING F I G U R E1 9 RECOMMENDED PIPINGFOR REPLACEMENT STEAMBOILER_ONE-PIPESYSTEM -L2- tl EffiHook-up Heater V: Tankless & Storage Section t TABLEVI STEAMAND FORCEDHOT WATER BOILERTANKLESSHEATERRATINGS TANKLESS HEATER HOOK.UP Install as shown in Figure 20 (water boiler) or Figure 21 (steamboiler). 2681268Vcannot use a tankless heater. 'lntermlttent 1. Install automatic mixing valve. 2. Install flow regulating valve. Size accordingto intermittent draw of heater as shown in Table VI. 3. Operating control with a small differential scaleis recommended.Install in temperature control tapping in heater plate. 4. In hard water areas,it is advisableto softencold domestic supplywater to tanklessheaterto preventlime build-up. FLOW coLD FEGULATINGWATER VALVE SUPPLY Heater No. Draw GPM 100oF. Average Temp. Rlse 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 STEAM 368 468 568 668 768-968 35-S.29 35-S-29 35-S29 35,S29 3s-s-29 3.00 3.25 3.50 375 4.00 2.OO 2.70 3.30 4.00 4.60 " IemperaIUre. Continuous draw-no +JACKET . FFONT recovery period HEATER MIXED MIN, t 112" sl4" 112" 112" 314" 112" 112" E4" 314" 112" 34" g4 314" 314 314' 314 314' 314 84" 314 314" I Not avarlable on 268/268V boilers 62-2-EStorageHeater cannot be used with 268i268V thru 568/568V forced hot water boilers or any size steam IEE OUTLET Temp. Control Taooino STORAGEHEATERHOOK.UP (forced hot water boiler only) CONTROL ,"o., ---I-I lnlet and Outlet Taooinos ratingsbasedon 60 PSIGdomeslicwaterpressureat heater. Werl-McLain ' Gallonsol waterDerminuteheatedlrom 40o lo 140oF.wilh 200"F boilerwater INLE\ BRASS ELBOW "Continuous Draw GPM 10 0 . F Temp. Rise Boilerl Size _t COLD F I G U R E2 0 TANKLESSHEATERPIPING(WATERBOILER) boiler. 1 . Locate tank as high as possible above boiler. 2 . 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 upward 1 inch for each 10 feet 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 as few elbows and pipe fittings as possible TABLEVII STORAGEHEATERRATINGS Boiler Size' :/a" TEMPERATURE 668 968 668V-768V TAPPING 180o Boiler Water Healer Capaclty Gallons 40o-1 40o Rise Storage Heater Number 62-2-E 50 in 3 Hours 212' Boiler Water Hester Capacily Gallons 400-140" Rlse 70 in 3 Hours Recommended 75-125 Gallons StoraqeTank 50-90 Gallons 'No. 62-2-Estorageheatercannotbe usedwith 268/268Vthrough568/568Vwaterboilersor COLD WATER SUPPLY I I with any steamboilers. PREssUAE ,i;* L lnt E TEMPER^TURE A + }l_ !'1- {re F_ OP€RAI \ r II t- t ;iru?. 'gl!9! NC n {t AUTOMATIC MIXING VALVE xor COLD F I G U R E2 1 TANKLESSHEATERPIPING(STEAMBOTLER) -13- ,, 'F^'t -ffi- Installation & Burner Boilers-Control Vl:Non-packaged Section *x ' s rurppue (aRess) Failure to properly install, pipe and wire boiler controls may result in severe damage to boiler, building and personnel. jree (aness) WATERBOILERCONTROLS 1. Install control where shown on tapping table, page 5. STEAMBOILERCONTROLS 1 . 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 pressure limit control' See Figure 23' jrt NIPPLE (BRAss) OIL BURNER For B-68/68Vboiler: 1. Placegasketover end ofair tube. 2. Looselyscrewthree mounting bolts into boiler mounting plate. Mount burner. A HIGH LIMIT PRESSURE CONTROL Tighten mounting bolts. For A-68/68V boiler: 1 STEAM GAUGE FoR olxrjNreer-E 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 be flush to 1/ainch recessedfrom inside wall of combustion chamber. ;fstneereuu * x g t t t P P u e- '(ennss) f srneerELL e{, jree LOW WATER C U T . O F F* 6 7 W P FIGURE 23 STEAMCONTROLS Vll: Wiring& FuelLinePiping Section WIRING For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electrical shock hazard. Wiring must comply with the National Electrical Code and any additional national, state, or local codes. Seewiring diagram, page 15 for proper wiring. -14- All safetycircuit wiring must be N.E.C.Class1. For any additional electrical safetycontrols,use No. 14 gatge wire. Electrical supply wiring to burner should be No. 14 gaugeor heavier with fused disconnectswitch. Be sure boiler is properly groundedat switch box. FUELLINEPIPING Referto separateburner manualand any local or national t/ code requirements which may apply to sizing and installing the fuel line piping. = N E.^a I *i3a9. 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T; i 1U E Bll @a ?z >P za 5 o I c lJ E6 f o E > ;< eoE f L tr E zEU o> F *-G <='- o z=* @-i t : G o\ -p = .<E oiiF <*!! fir o< $e rE oooooo : N6 N u 0 -i :NENO 9= fi9 o+ 5 E= e= , qa ol >H E5 I - Ai ; P E x *=' 6 SE E E 6 ,q: I ouJ Er IIJ F Ff t 3\ UUY a>;, Eb E E :o o > E 9 iY-:o .: i; x -E*8E u. :. ,= ., Y 9 gl.s -r ov = !E o : : 6 E 8 9 ;5 = 6 E;r4 il: iqt,E 5. sl 26.82 ; E: E9EP..g : q a#?3EE SE' EE;EEP! :E E!EEEeE" +x 9F)::y; O nr "* -- - X iri P .=6e;nen 5gE=E+#=* -ffiAdjustments Vlll:Final Section ADJUSTMENT BURNER WATER TREATMENT Never use petroleum based stop-leak compounds. Water seal deterioration will occur, resulting in leakage between sections. Final burner adjustments must be made using combustion test equipment to assure proper operation. DO NOT FIRE BOILER WITHOUT WA. TER OR SECTIONSWILL OVER. 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. HEAT. 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. Inhibited propylene glycol is recommended. DO NOT use undiluted or automotive type antifreeze. 507o solution provides maximum protection to about - 30'F. Local codes may require a back-flow preventer or actual disconnect from city water supply. Determine quantity according to system water content. Boiler water content is listed on page 18. Follow antifreeze manufacturer's instructions. FILLINGWATERBOILER 1. Close manual air vents, drain cocks, and automatic air vent, if used. Z. 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. SKIMMINGSTEAMBOILER Clean newly installed steam boiler to remove oil and grease. Failure to properly clean can result in violent fluctuations ofwater level, water passing into steam mains, or high maintenance costs on strainers, traps and vents. Do il?JJ." productt t" petroleum based with each application. 1. Provide 11/2" piping from boiler skim tapping to floor drain. Open automatic air vent two turns, if used. 2. Adjust waterline to midpoint of skim piping. 2 . Fill to correct system pressure. Correct pressure will vary t). Refer to burner manual for start-up. Adjust air band to provide a clean yellow flame without smokey tips. 4 . 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. 6 . Close, then open automatic air vent, if used, one full turn for normal boiler operation. FILLINGSTEAMBOILER 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. 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 several hours. 6. Drain boiler. While boiler is warm but NOT HOT, flush all interior surfaces under full pressure until drain water runs clear. 7. Remove skim piping and plug tapping. 3. Boiler water pH 7.0 to 8.5 is recommended. 8. Close drain cock. Fill with fresh water to waterline. Start burner and steam for 15 rninutes to remove dissolved gases.Stop burner. 4. Follow skimming procedure. 9. Check traps and air vents for proper operation. -16- G -ffiProcedure lX:Check-out Section ) PROCEDURE CHECK.OUT (Check-offstepsas completed.) n tl Water boiler: a. System properly filled with water? 7. Limit control set to design temperature or pressure requirements of system? Maximum limit setting -240'F. (water boilers)-15 psi (steam boilers). b. Air purged from system? c. Automatic air vent, if used, open one turn? u2 8. For n"rultiple zones, flow adjusted so it is about the same in each zone (water boilers only)? Steam boiler: ii. Boiler properly filled rvith rvater? 9. Thermostat heat anticipator set properly? Refer to wiring diagram. b. Svstem vents operating properly'? c. Boiler properly skimmed? 'a 6. Test ]imit control: While burner is operating, move indicator of limit control below actual boiler water temperature or pressure. Burner should go off. Circulator should continue to operate (water boilers only). Raise limit control above boiler water temperature or pressure and burner should reignite. tl Air purged lrom oil piping? Piping checked for leaks? I'- A Proper draft and burner flame? Final adjustment made with combustion test equipment? L] D. Test safety controls: If boiler is equipped with a low water cut-off or additional safety controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when controls are tested. When safety devices are restored, burner should reignite. 10. Boiler cycled with thermostat? Raise to highest setting. Boiler shouid go through normal start-up cycle. Lower to lowest setting. Boiler should go off. LI 11. Several operating cycles observed for proper operation? L ] 12. Room thermostat set to desired temperature? t_ 13. All instructions shipped with boiler reviewed with owner or maintenance person, returned to envelope and given to owner or displayed near boiler? LJ 14. On initial start-up, check for leaks in system piping. If found. renair at once. Installationand ServiceCertificate B O I L E RM O D E L B T UI N P U T CP NUMBER SERIES DATEINSTALLED L l Installation havebeenfollowed. instructions E Check-outsequencehas beenperformed. I Abou" information is certiliedto be correct. n receivedand leftwithowner/maintenance lnformation oerson lnstaller (Company) (Address) (Phone) (lnstaller'sSignature) -17- [HIl- - X:Ratings-Data Section r} @, N E TI = B = B R A T I N G S - iDOE HEATING I=B=B MBH CAPACITY BOITER STTAM STEAM WATEB BURNER CAPACITY MBH WATER s0.FT. MSlt GPH STEAM NUMBER PREFIX 74.8 oo o.70 P 268t268V 14 368 368V 0.95 0.9s 113 A,B, P 468 468V 1.25 1.25 149 A,B, r 568 568V 1.50 1.50 179 A,B, P 668 668V 1.80 216 A,B, P 2.05 2.05 246 ?48 248 770 768V A,B 868 230 2691 2691 A,B 968 2.55 298t 2981 A,8, f /od 84.8 JC3 14 51 51 a: 181 .t 8l ':' 218 675 111.8 SIZE INCHES 8x8 99.1 99.1 8x8 31.3 8x8 8x8 8x8 HEIGHT FEET WATER P6St''qprB-63l/ TA rt B{S 15 7.O 15 15 't5 13.3 3.3 3.3 11.2 4.9 4.9 12.4 8.6 10.2 't0.2 6.5 6.5 13.6 IJ.J 8.6 l5 '15 STEAM (ToWalerline) 157.4 157.4 8x8 8x8 15 189.6 189.6 8x8 5 5 1.8 1.8 8 .1 8.1 14.8 8x8 184.5 215.7 215.7 8x8 8x8 5 5 3.4 3.4 9.7 9.7 to. I 840 201.8 233.9 930 223.6 2 5 9 . 1 134.3 162.0 218 1.80 (GAt.) EOILERWATERCONTENT l=8=RCHIMNEY 12 12 20 zt.J 17.4 20 22.9 18.6 t Basedon standardtest proceduresprescribedby the UnitedStatesDeparlmentof Energyat combustionconditionof 130/oCOz I e f 1. 3 3 3 .A n a d d i t i o n aal l l o w a n c se h o u l db e m a d ef o r u n u s u apl i p i n g e l 1. 15 . S t e a mr a t i n g sa r e b a s e do n a n a l l o w a n c o r a t i n g sa r e b a i e d o n a p i p i n ga n d p i c k - u pa l l o w a n c o a n d p i c k - u pl o a d s . I B RG r o s sO u t p u t 6 8 R E A RFLUEOUTLET L'flN) BOILER slzE A flN) 268 PACKAGEDSTEAM PACKAGED f,R KNOCKEDOOWN WATEROR STEAM WATER B flN) 368 91lz 33/g 13c/e 468 12112 13s/e 169/s s68 15112 63/s 19:/e oob 18112 19s/e 22sle 21112 22sla 25qe 768 868 968 'Jacket R E TU R N 10s/e 9tlz 25tla 24112 28slB 28114 27tlz 31 :/a rl -trr ^3 ,iL PACKAGED FRoNr (wArER) extension increases length 1 7112in I-- | I Z -ft SKIM TAPPING SUPPLY -t PACKAGED FRONT(STEAM) D ^Z WATER L I NE f 1 5 "m i n i m u m heaterclearance loE TCONDARY IR TTER ,l' ASSEMBLEDFRONT t ll RETURN WATER_-+ ,' 4l l I 1 ll .l to -18- -ffi68 REARFLUEOUTLET(Continued) ) HEATERLOCATION PACKAGED srDE (STEAM) PACKAGED srDE (WATER) ul S T EA M HEATER L E F TS I D E ASSEMBLED -l 20 r6i 1. .1 F-OR7,, VENTPIPE 2" RETURN STEAM 1__ ! ,r Tr6- BACK INTERMEDIATE -19- -wfl68VTOPFLUEOUTLET BOILER SIZE a INCHES L' A B 268V+ 5 91lz 5s/re 103/8 E 368V 5 9tlz 5e/rs l3gie 468V 6 12112 I tt16 133/g 568V o l5tlz I tt16 16s/e 668V 7 18tlz T II16 19s/a 768V 7 2ltlz Ttlta 22sla + 268V availableas packagedunit only .Jacket extensionincreaseslength.l7112 in RET URN WATER HEATER SECONDARY AIR a)'ow rNFRoNr . PLATE SHUTTER ,t' RETURN r- -{- 'c43 J II -1 PACKAGED FRONT(WATERONLY) PACKAGED SIDE(WATERONLY) to t- t* 4-?= -{F l- lr'" 42+ --1 A l.1=, i tI ' at_; -L ,l ;s- f ASSEMBLED LEFT SIDE -20- P|PE ll, il i '.1 t_J_-______, l*vENr INTERMEDIATE BACK ! -ffiParts Xl:Replacement Section I, 7-=_? "/ 68 B O I L ER K .///' ,{ \ 6 14 --/.'; 13 PARTSLIST 15 REF. NO. 2 3 D DESCRIPTION PART NUMSER FrontSection,P-68-W(6813) FrontS€ction.P-68'S,A or B-68-Wor S (6813) 316,60 . 2 1 6 316-60 .249 lntermediate Section(6815) Intermediat€ Sectionw/Lugs,A or B'868/968-Wor S (6816) 31 6-60 31 6-60 "T" BackSsction,Wide, P-68-S,A or B-68-Wor S (6818) (€xcspt 868/968) "T" Back Ssction,Wide w/Supply,A or B-868/968-W or S (6819) thru P-768-W(6814) Back Section,Narrow,P-268-W/P-468-W Back Section,Wide, P-368-W(6817) REF. NO. Reg Hex Nut,3/8 Washer, Pla n Type A A8 -222 -225 592-800-007 592-800-010 6 Ti€ Rod-1/2 x 81/2(P-268-W) 1/2x 10(P-368-W) 1/2x 111/2(P-468-W) 1/2x 141/2(P-568-W) 112x 17112(P-668-W\ 112x 2O112(P-76A-W\ 1/2x 10 (P-368-S,A or B-368-Wor S) 1i2x 13 (P-468-S,A or B-468-Wor S) 1/2x 161/4(P-568-S,A or B-568-Wor S) 1/2x 191/2(P-668-S,A or B-668-Wor S) 112x 2211a (P-768-5,A or B-768-Wor S) 1/2x 111/2(A or B-868-Wor S) 1/2x l3 (A or B-868/968-W or S) 112x 14112lAorB-968-Wor S) 1/2x 51/2(A or B-868/968-W or S) Reo. Hex Nut. 1/2-13 1/2HelicalSpring Loclkwasher, Tie Rod._q8 x 7112(P-268-W\ E8 x 9(P-368-W) 18 x 101h(P-468-W) q8 x 131/2(P-568-W) q8 x 161/4(P-668-W) q8 x 191/2(P-768-W) qB x 9 (P-368-S,A or B-368-w or S) 3/8 x 12 (P-468-S) 3/8 x 12112 (A or B-468-Wor S) q8 x '15(P-568-S,A or B-568-Wor S) E8 x 18 (P-668-S,A or B-668-Wor S) 3i8 x 21 (P-768-S,A or B-768-Wor S) gB x 101/2(Aor 8-868W or S) qs x !31/2(Aor 8-968W or S) Es x 121/2(A or 8-868/968W or S) 560-234-4661 560-234-4671 560-234-4691 560-234-4714 560-234-4744 560-234-4781 560-234-4674 560-234-4681 560-234-4734 560-234-4761 560-234-4794 560-234-4691 560-234-4681 560-234-4714 560-234-4641 I I 560-234-403t 560-234-4001 560-234-4071 560-234-4174 560-234-430t 560-234-435t 560-234-400t 560-234-408t 560-234-4124 560-234-4224 560-234-4331 560.234.4374 560-234-407I 560-234-4174 560-234-4124 I T 438 x 1 00 x .083 Coge Seal (7'pef toinl) 591 -641,862 cleanout Plate 450,030-949 450-030-950 450-030-951 450-030-952 450-030,953 450-030,954 450-030955 8 cleanoutPlateGasket-268/368 468 568 668 768 868 968 591-22 591-22 591-22 591-22 591 22 591-22 591-22 I Rectangular Heater Cover Plate (Steam) Tankless Heater w/Gasket (Steam) 35-S-29 450-030-934 590-921-666 Rectangular Healer Cover Plate Gasket (Sleam) 590-317-579 RoundHeaterCoverPlale-q4" Opening(Water) 11/2o " p e n i n g( s t e a m ) TanklessHeaterw/Gasket(water)-E-624 E-626 E-632 w/Gasket 62-E-2 Healer Storaqe 592-243-217 592,243-216 590-921-670 590-921-675 s90-921-658 s90-921-665 316-601-234 316-601-219 316-601-228 ElaslomerSeal,6" (top) Elastom€rSeal.3" (bottom) PART NUMBER 7 316-601-231 4 5 DESCRIPTION 10 1 14 15 17 I Can be purchasedat localsupplyhouse. NOTE: Orderburnerpartsdirectlyfromburnermanufacturer. '18 268/368 468 568 668 764 868 968 .260 .261 .262 .263 .264 .265 .266 RoundHeaterCoverPlateGasket(Wate0 s90-317-495 UniversalBurnerMountingPlateAss'y (includesburner and insulation) mountingplate,refractory, FrontRefractory Cerafeltlnsulation 343-500-540 s91-000-061 591-221-054 ObservationPortShutter SecondaryAir Shutter 460-039-867 460-039-898 Rear Refraclory Back RelractoryPin RefractoryBlanket 268/368 468 568 668 768 868 968 59 59 59 59 59 59 59 59 59 ReturnPipe l\,lanifold 591-124-002 -2L- -000-060 -000-054 -221-235 -221.230 -221-231 -221.232 -221-233 -221-234 .221-236 -um'--t2 ' ;l 3ry_ 68V BO IL E R i- r Oi i*'f ' '-:" ->-.=\>/ -: 'r :_g, t\ t Jt, -r)y "", 5 l; -16 t"t a \ .,, 13 ?' ./ .6d ."'/ //E ,..f 15 PARTSLIST REF. NO. DESCRIPTION PAFT NUMBER FronlSection(6823) 316-60 1-237 2 Intermediate Section(6825) 316,601 243 3 A or BackSection,Wide, P-368V-W, B-368V-W(6827) BackSeclion,Narrow,P-468V-Wthru P768V-W,A or B-468V-Wlhru A or B-768V-W(6824) 5 6 7 REF. NO. 8 3 16 - 6 0 1 , 2 4 6 316-601-240 ElastomerSeal,6" (top) Elastomerseal. 3" (bottom) s92-800-007 592-800-010 Tie Rod-1/2 x r1/2(268V) 112x 0 (368V) 112x 11/2(468V) 112x 4112 (568V) 112x 7112 (668V) 112x r01/2 (768V) R e g . H e x N u t , 1 it - 1 3 Lockwasher, l/2 telical Spring '112(268V) Tie Rod-98 x q B x | (368v) 3/8 x 01/2(468V) q8x 31/2(568V) 98x 61/4(668v) g8x 91/2(768V) Reg. Hex Nut, 3 Washer, Plain T / p eA q 8 - . 4 3 8 x1 . 0 0 x . 0 8 3 560-234-4661 560-234-4674 560-234-4691 560-234-4714 560-234-4744 560-234-4781 I I 560-234-4031 560-234-4001 560-234-407I 560-234-4174 560-234-4301 560-234-4351 I T Cope Ssal (7' per joinl) 591-641-862 cleanoutPlate-268V/358V 468V 568V 668V 768V 450-030-960 450-030-961 450-030-962 450-030-963 450-030.964 13 14 lc '16 17 '18 19 -22- OESCRIPTION PART NUMBER CleanoutPlateGaskel-268V/368V 468V 568V 668V 768V 591-22 .260 591-22 . 2 6 1 591,22 .262 591-22 263 591-22 264 FloundHeaterCoverPlale-314"Opening(Wator) TanklessHeaterw/Gasket(Wateil-E-624 E-626 E-632 592,243217 590-921-670 590,921-675 -658 590-921 RoundHeaterCoverPlateGasket(Wale0 590-317-495 UniversalBurnerMountingPlaleAss'y (includesburner mountingplate,refractory,and insulation) Front Refractory CerafeltInsulation 343-500,540 591-000-061 591-221-054 ObservationPon Shutter SecondaryAir Shutter 460-039-867 460-039-898 Rear Relractory Back RefractoryPin RetractoryBlanket 268V/368V 468V 568V 668V 768V 59 59 59 59 59 59 59 VerticalFlueCollector268V/368V 468V 568V 668V 768V 450-020-100 450-020-1 01 450-020-102 450-020-1 03 450-020-104 ReturnPioe Manifold 591-124-002 -000-060 -000-054 -221"235 -221.230 -221-231 .22't-232 -221-233 U