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Model FLE

Field Erectable Flexible Watertube Boiler


Assembly Instructions

750-192
07/09
! WARNING
DANGER ! WARNING
DANGER
If the information in this manual is not fol- Improper installation, adjustment, service, or
lowed exactly, a fire or explosion may re- maintenance can cause equipment damage,
sult causing property damage, personal personal injury, or death. Refer to the Opera-
injury or loss of life. tion and Maintenance manual provided with
the boiler. Installation and service must be
— Do not store or use gasoline or other performed by a qualified Cleaver-Brooks ser-
flammable vapors and liquids in the vicin- vice provider.
ity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS ! WARNING
DANGER
• Do not try to light any appliance.
Be sure the fuel supply which the boiler
• Do not touch any electrical switch; do
was designed to operate on is the same
not use any phone in your building.
type as specified on the boiler name
• Immediately call your gas supplier
plate.
from a neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier, ! WARNING
DANGER
call the fire department. Should overheating occur or the gas sup-
— Installation and service must be per- ply valve fail to shut off, do not turn off or
formed by a qualified Cleaver-Brooks, disconnect the electrical supply to the
service agency or the gas supplier. boiler. Instead turn off the gas supply at a
location external to the boiler.
! WARNING
DANGER
To minimize the possibility of serious per- ! WARNING
DANGER
sonal injury, fire or damage to the equip- Do not use this boiler if any part has been
ment, never violate the following safety under water. Immediately call your Cleav-
rules. er-Brooks service representative to in-
— Always keep the area around the boiler spect the boiler and to replace any part of
free of combustible materials, gasoline, the control system and any gas control
and other flammable liquids and vapors which has been under water.
— Never cover the boiler, lean anything
against it, stand on it, or in any way block Notice
the flow of fresh air to the boiler.
This manual must be maintained in legi-
ble condition and kept adjacent to the
Notice
boiler or in a safe place for future refer-
Where required by the authority having ence. Contact your local Cleaver-Brooks
jurisdiction, the installation must conform representative if additional manuals are
to the Standard for Controls and Safety required.
Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.

ii
! WARNING
DANGER ! WARNING
DANGER
The boiler and its individual shutoff valve The installation must conform to the re-
must be disconnected from the gas sup- quirements of the authority having jurisdic-
ply piping system during any pressure tion or, in the absence of such
testing of that system at test pressures in requirements, to UL 795 Commercial-In-
excess of 1/2 psi (3.5 kPa). dustrial Gas Heating Equipment and/or
the National Fuel Gas Code, ANSI Z223.1

iii
Notes

iv
CLEAVER-BROOKS
Model FLE
Field Erectable
Flexible Watertube Boiler
Assembly Instructions

 Cleaver-Brooks 2009

Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative.

Manual Part No. 750-192


07/09 v Printed in U.S.A.
! WARNING
DANGER
DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL
APPLICABLE SECTIONS OF THIS MANUAL.

DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY
UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE
PERSONAL INJURY OR DEATH.

TO: Owners, Operators and/or Maintenance Personnel

This operating manual presents information that will help to properly operate and care for the equipment. Study its con-
tents carefully. The unit will provide good service and continued operation if proper operating and maintenance instruc-
tions are followed. No attempt should be made to operate the unit until the principles of operation and all of the
components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe
personal injury or death.

It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who
are servicing, repairing or operating the equipment, in all safety aspects.

Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical
and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however,
proper operating techniques and maintenance procedures must be followed at all times. Although these components af-
ford a high degree of protection and safety, operation of equipment is not to be considered free from all dangers and
hazards inherent in handling and firing of fuel.

Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely
free him of certain repetitive chores and give him more time to devote to the proper upkeep of equipment.

It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instructions
can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the
responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before at-
tempting to operate, maintain, service, or repair this equipment.

Because of state, local, or other applicable codes, there are a variety of electric controls and safety devices which vary
considerably from one boiler to another. This manual contains information designed to show how a basic burner operates.

Operating controls will normally function for long periods of time and we have found that some operators become lax in
their daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to
uneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness and
deficiencies in testing and maintenance.

It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly and yearly main-
tenance activities and recording of any unusual operation will serve as a valuable guide to any necessary investigation.
Most instances of major boiler damage are the result of operation with low water. We cannot emphasize too strongly the
need for the operator to periodically check his low water controls and to follow good maintenance and testing practices.
Cross-connecting piping to low water devices must be internally inspected periodically to guard against any stoppages
which could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected
frequently to check for the presence of foreign substances that would impede float ball movement.

The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be inspected fre-
quently to check for the presence of any mud, sludge, scale or corrosion.

It is essential to obtain the services of a qualified water treating company or a water consultant to recommend the proper
boiler water treating practices.

The operation of this equipment by the owner and his or her operating personnel must comply with all requirements or
regulations of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsis-
tency between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks be-
fore proceeding.
vi
CONTENTS
CHAPTER 1
General Description
1. The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Transportation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
3. Order of Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
4. Pressure Vessel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
5. Casing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
6. Burner and Fuel Piping Installation . . . . . . . . . . . . . . . . . . . . . 1-7
7. Trim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

CHAPTER 2
Pressure Vessel Assembly
1. Preparation for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2. Position the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3. Level the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
4. Positioning the Lower Drum on the Base . . . . . . . . . . . . . . . . . 2-3
5. Upper Drum Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
6. Check All Drum Holes and Studs . . . . . . . . . . . . . . . . . . . . . . 2-4
7. Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
8. Ferrule Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
9. Pass Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
10. Installation of Pressure Vessel to Base . . . . . . . . . . . . . . . . 2-16
11. Pressurized Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

CHAPTER 3
FLE Casing Assembly Procedures
1. Install Wetpack around Vent Tube . . . . . . . . . . . . . . . . . . . . . 3-8
2. Install Backing Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3. Install Rear Wall Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
4. Drill Rear Sight Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
5. Wetpack Installation Around Lower Drum . . . . . . . . . . . . . . . 3-14
6. Finish Installing Backing Plates . . . . . . . . . . . . . . . . . . . . . . 3-14
7. Install Front Wall Section . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
8. Install Roof Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
9. Install Burner Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
10. Install Lift Lug Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
11. Install Drum Packing and Seal Plates . . . . . . . . . . . . . . . . . 3-18
12. Install Insulation Under Tubes . . . . . . . . . . . . . . . . . . . . . . 3-19
13. Install Pass Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
14. Prepare for Inner Casing Installation . . . . . . . . . . . . . . . . . . 3-20
15. Prepare Inner Panels for Installation . . . . . . . . . . . . . . . . . 3-21
14. Install Inner Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
17. Install Outer Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

CHAPTER 4
Burner Assembly, Gas Train, and Boiler Controls Installation
1. Burner Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
2. Burner Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
3. Gas Train Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4. Electrical Connections and Layout . . . . . . . . . . . . . . . . . . . . . 4-3

vii
viii
Model FLE Assembly General Description

The hot water unit has a single rear flanged external


CHAPTER 1 rear downcomer while the steam unit has flanged
General Description downcomers on both the front and rear. All units
have top and bottom drums. In the hot water unit,
1. The Boiler . . . . . . . . . . . . . . . . . . . . . . . . 1-1 the top and bottom drums are the same diameter,
2. Transportation and Handling . . . . . . . . . . . 1-2 but in the steam units, the top drum of a steam unit
3. Order of Assembly . . . . . . . . . . . . . . . . . . 1-4 is larger than the bottom. The pressure vessel is
4. Pressure Vessel Assembly . . . . . . . . . . . . . 1-4 designed and fabricated in accordance with the
5. Casing Assembly . . . . . . . . . . . . . . . . . . . 1-5
ASME Boiler and Pressure Vessel code.
6. Burner and Fuel Piping Installation . . . . . . . 1-7
7. Trim Installation . . . . . . . . . . . . . . . . . . . . 1-7
The heated area of the pressure vessel is contained
1. The Boiler within an insulated casing that is composed of
removable, formed steel panels. The fuel/air mixture
The Cleaver-Brooks Model FLE Boiler is a field- from the burner combusts in the furnace area, then
erectable, five-pass, steel boiler. Its flexible, exit the furnace (pass one) to flow through four
replaceable, water-tubes are formed and arranged to additional front-to-back passes formed by the
direct the flow of combustion gases through the arrangement of the watertubes within the boiler
boiler as illustrated in Figure 1-1. casing. In the fifth pass, the gases flow around the
top drum before exiting the boiler casing through the
stack vent.

Figure 1-1. Five-Pass Construction of the Cleaver


Brooks Model FLE Boiler

750-192 1-1
General Description Model FLE Assembly

2. Transportation and Handling


Table 1-1 shows the approximate weights and sizes
of the various components. The total weight of each
shipping crate handling should be done with an
appropriately sized forklift or other suitable heavy
lifting devices.

Figure 1-2. Model FLE Boiler Tubes Being Readied


to Ship
Table 1-1: Boiler Components, Approximate Weights and Sizes
PARTS HOT WATER
DESCRIPTION INFO 150-250 300-350 400-600 700-900 1000-1200
Base Assembly PART NO 315-1124 315-1169 315-1180 315-1194 315-1203
(Insulated) APPROX. SIZE (in) 68x42 74x45-1/2 94-1/5x47-1/2 116x53-1/2 140x53-1/2
WEIGHT (lbs) 630 710 950 1440 1690
Front Wall PART NO 315-1128 315-1265 315-1177 315-1191 315-1201
APPROX. SIZE (in) 68x33-1/2 77x40 77x40 84x45 84x45
(Insulated) WEIGHT (lbs) 110 130 140 175 175
Rear Wall PART NO 315-1129 315-1165 315-1176 315-1190 315-1190
Large Piece APPROX. SIZE (in) 67x33-1/2 77x40 77x40 84x45 84x45
(Insulated) WEIGHT (lbs) 110 125 140 175 175
Rear Wall PART NO 315-1140 315-1279 315-1281 315-1282 315-1282
Corner Piece APPROX. SIZE (in) 23x16-1/2 20x19 26x20 27x23 27x23
(Insulated) WEIGHT (lbs) 30 35 40 45 45
Roof Assembly PART NO 315-1127 315-1167 315-1178 315-1192 315-1202
(Insulated) APPROX. SIZE (in) 75x42 74x38 95x39 118x45 140x45
WEIGHT (lbs) 185 215 280 370 430
Upper Drum PART NO 270-2703 270-2704 270-2705 270-2706 270-2707
Assembly APPROX. SIZE (in) 14x54-1/4 16x60-1/4 17x81-1/4 20x102-1/2 20x126-1/2
WEIGHT (lbs) 320 340 540 620 690
Lower Drum PART NO 270-2708 270-2709 270-2710 270-2711 270-2712
Assembly APPROX. SIZE (in) 14x55 16x60-1/4 17x81-1/4 20x102-1/2 20x126-1/2
WEIGHT (lbs) 300 230 510 590 660
Inner Casing PART NO * * * * *
Panels APPROX. SIZE (in) 67x32 74x36 79x28 86x30 86x28
(Insulated) WEIGHT (lbs) 50 53 57 61 61
Outer Casing PART NO 315-1130 315-1164 315-1175 315-1189 315-1198
Panels APPROX. SIZE (in) 71x22 75x24 80x23 87x27 87x25
(Insulated) WEIGHT (lbs) 38 43 40 39 38
Burner Door PART NO ** ** ** ** **
APPROX. SIZE (in) 20x20 20x20 26x26 26x26 26x26
WEIGHT (lbs) 120 120 240 240 240
Tubes PART NO ** ** ** ** **
APPROX. SIZE (in) 14x28-1/2 16x31-1/2 17x43.5 20x51.75 20x63.75
WEIGHT (lbs) 1300 2000 2300 3300 4000
TOTAL WEIGHT 3900 5000 7600 8500 10000
* Various part numbers are used for each size
** Part number depends on burner size required.

1-2 750-192
Table 1-1 cont’d
PARTS HIGH PRESSURE STEAM LOW PRESSURE STEAM
DESCRIPTION INFO 150-250 300-350 400-600 700-900 1000-1200 150-250 300-350 400-600 700-900 1000-1200
Base Assembly PART NO 315-1224 315-1169 315-1180 315-1194 315-1203 315-1224 315-1169 315-1180 315-1194 315-1203
(Insulated) APPROX. SIZE (in) 60x42 74x45-1/2 95x47-1/2 116x53-1/2 140x53-1/2 60x42 74x45-1/2 95x47-1/2 116x53-1/2 140x53-1/2
WEIGHT (lbs) 630 710 950 1440 11690 630 710 950 1440 11690
Front Wall PART NO 315-1216 315-1229 315-1238 315-1249 315-1249 315-1216 315-1229 315-1238 315-1249 315-1249
Large Piece APPROX. SIZE (in) 77x33 81x37 85x39 97x45 97x45 77x33 81x37 85x39 97x45 97x45
(Insulated) WEIGHT (lbs) 110 125 125 170 170 110 125 125 170 170
Front Wall PART NO 315-1286 315-1288 315-1290 315-1292 315-1292 315-1286 315-1288 315-1290 315-1292 315-1292
Corner Piece APPROX. SIZE (in) 32x17 36x19 34x20 40x23 40x23 32x17 36x19 34x20 40x23 40x23
(Insulated) WEIGHT (lbs) 20 25 30 35 35 20 25 30 35 35
Rear Wall PART NO 315-1217 315-1228 315-1237 315-1248 315-1248 315-1217 315-1228 315-1237 315-1248 315-1248
Large Piece APPROX. SIZE (in) 77x33 81x37 85x40 97x46 97x46 77x33 81x37 85x40 97x46 97x46
(Insulated) WEIGHT (lbs) 130 145 155 210 210 130 145 155 210 210
Rear Wall PART NO 315-1285 315-1287 315-1289 315-1291 315-1291 315-1285 315-1287 315-1289 315-1291 315-1291
Corner Piece APPROX. SIZE (in) 40x21 44x23 42x24 40x23 40x23 40x21 44x23 42x24 40x23 40x23
(Insulated) WEIGHT (lbs) 25 30 35 40 40 25 30 35 40 40
Roof Assembly PART NO 315-1215 315-1230 315-1239 315-1250 315-1260 315-1215 315-1230 315-1239 315-1250 315-1260
(Insulated) APPROX. SIZE (in) 68x34 74x37 95x40 116x45 140x45 68x34 74x37 95x40 116x45 140x45
WEIGHT (lbs) 185 215 280 370 430 185 215 280 370 430
Upper Drum PART NO 270-1527 270-1528 270-1529 270-1530 270-2510 270-1523 270-1524 270-1525 270-1526 270-2582
Assembly APPROX. SIZE (in) 20x98 20x104 20x126 24x150 24x182 20x98 20x104 20x126 24x150 24x182
WEIGHT (lbs) 890 930 1075 1500 1750 975 1020 1170 1660 1910
Lower Drum PART NO 270-1519 270-1520 270-1521 270-1522 270-2513 270-1515 270-1516 270-1517 270-1518 270-2581
Assembly APPROX. SIZE (in) 8x96 8x104 10x126 10x150 10x182 8x96 8x104 10x126 10x150 10x182
WEIGHT (lbs) 310 325 515 600 705 310 325 515 600 705
Inner Casing PART NO * * * * * * * * * *
Panels APPROX. SIZE (in) 76x32 83x35 87x32 100x30 100x28 76x32 83x35 87x32 100x30 100x28
(Insulated) WEIGHT (lbs) 57 60 63 55 55 57 60 63 55 55
Outer Casing PART NO 315-1218 315-1227 315-1236 315-1247 315-1257 315-1218 315-1227 315-1236 315-1247 315-1257
Panels APPROX. SIZE (in) 80x22 84x23 88x23 100x23 100x23 80x22 84x23 88x23 100x23 100x23
(Insulated) WEIGHT (lbs) 42 48 43 45 44 42 48 43 45 44
Burner Door PART NO ** ** ** ** ** ** ** ** ** **
APPROX. SIZE (in) 20x20 20x20 26x26 26x26 26x26 20x20 20x20 26x26 26x26 26x26
WEIGHT (lbs) 120 120 240 240 240 120 120 240 240 240
Tubes PART NO 93-3200 93-3200 93-3200 93-3200 93-2729 93-3200 93-3200 93-3200 93-3200 93-2729
APPROX. SIZE (in) 25-3/4x60 29-37x64 36-3/4x67 38-3/4x77 38-3/4x77 25-3/4x60 29-37x64 36-3/4x67 38-3/4x77 38-3/4x77
WEIGHT (lbs) 1400 1700 2500 3600 4400 1400 1700 2500 3600 4400
TOTAL WEIGHT 5700 5700 6200 7900 10200 11700 6200 7900 10200 11700
* Various part numbers are used for each size
** Part number depends on burner size required.
General Description Model FLE Assembly

3. Order of Assembly
The assembly of the pressure vessel and casing will
be easier if all of the component parts are sorted
and arranged to be easily accessible in the working
area. If there is not enough room in the work area
for all the parts, only those that will be needed for
the day’s work should be brought into the work
area.
Assembly of the boiler can be regarded as a four
step process. The four steps are:

1. Pressure vessel assembly and Figure 1-3. ProFire burner mounted on a Model FLE
boiler
water side leak test (Chapter 2)
2. Casing assembly and fireside leak The following tools will be required to assemble
test (Chapter 3) the pressure vessel:
3. Burner assembly and gas train
installation (Chapter 4) • Small and large level
4. Trim installation (Chapter 4) • Vice-grip clamp or strap wrench
• Chain fall and support strapping
• Lifting support
The boiler components are listed in Table 1-1. • Tube driving tools and 16 or 20 lb sledge hammer
Special assembly equipment likely to be required for • 5/8” die
each part of the assembly process is listed below. • Dulled chisel
• Slings and chains
There are three different types of insulation used in • Lifting and support devices (come-along, ratchet
the construction of the Cleaver-Brooks Flextube hoist, etc.)
• Caulking gun
Model boilers:
• Safety glasses, hearing protection and gloves
• Ceramic fiber- white, flexible, dry insulation, supplied • Suitable lifting equipment will be required to handle
in bulk roll or block the placement of the drums and the mounting of the
• Wet-pack- white, flexible, insulation saturated with completed vessel to the base
curing agent, supplied as rolls in sealed bags
• Fibrefax- white insulation, supplied in tubes

4. Pressure Vessel Assembly


Assembly of the pressure vessel will require the
following components (also refer to the packing list):
• Top and bottom drums
• Fanged bolts and gaskets
• Boiler tubes
• Base assembly
• Ceramic fiber pass seal insulation
• Tube sealant (LockTite 680)
• Anti-seize lubricant
• Tube retainers and fasteners
• Spray adhesive

Figure 1-4. Model FLE (Steam)

1-4 750-192
Model FLE Assembly General Description

The tools required to install the casing include:


Note: • Hand tools, 1/2” drive ratchet and sockets
• Building the vessel in a vertical position will require • Wedges or dulled chisel
support from the top. • Pry bars and tapered alignment pins
• Drum placement is best accomplished when the base • Cartridge caulk applicator
is used as an initial building jig. • Slings and chains
• A steam boiler will become structurally rigid with the • Lifting devices (come-along, ratchet hoist, etc.)
coupling of the front and rear Downcomers. • Razor knife, putty knife
• Check the levelness of the base to the lower drum • Four, 5 foot bar clamps
and subsequently the Downcomers and upper drum
frequently.

Full sledge hammer swings, organized tube delivery


and efficient clamping, will build a rhythm allowing
for the installation of a side of 40 tubes in two to
four hours.

The base of the boiler must be leveled before the


pressure vessel is mounted and fixed. Level the ends
first, followed by the sides at both corners

After building, mounting, leveling and securing the


pressure vessel, a leak test must be performed. The
test requires that all open fittings on the drums be
plugged or valved for the test. Refer to the
Dimension Diagram for fittings required.

5. Casing Assembly Figure 1-5. Model FLE (Hot Water)

Installing the casing will require:

• Front-end and rear-end walls and collar plates


• Roof
• Inner Casing panels
• Burner door
• Fasteners
• Insulation (ceramic fiber blanket and wet pack)
• Gaskets
• High temperature silicon sealant
• Outer casing
• Drum Spreader (hot water units)

750-192 1-5
General Description Model FLE Assembly

1. HIGH LIMIT PRESSURE CONTROL


2. OPERATING LIMIT PRESSURE CONTROL
5
3. MODULATION PRESSURE CONTROL
4. PRESSURE GAUGE
5. WATER COLUMN

1 2
3 4

Figure 1-6. Typical Gas Train


Figure 1-7. Trim Components (Hot Water)

1-6 750-192
Model FLE Assembly General Description

6. Burner and Fuel Piping Installation


Installing the burner requires:
• Burner,
• Gas and/or oil fuel delivery components,
• Piping, and
• Electrical conduit, fittings, etc.

7. Trim Installation
Installing the trim components requires:

• Relief valve(s)
• Burner firing controls
• Low water cutoff
• Conduit and wire
• Pipe components
• Standard electrical tools (conduit bender, wire puller,
etc.)
• Wiring diagram

NOTE: When the burner is being in-


stalled, a means of safely lifting the
burner will be required. Refer to the Op-
eration and Maintenance manual for
burner weights.

Additional parts included in the assembly kit include


standoffs. These are welded to the drum, front or
rear walls to allow ventilated mounting space for the
required safety and warning stickers.

750-192 1-7
General Description Model FLE Assembly

1-8 750-192
Model FLE Assembly Pressure Vessel Assembly

surfaces, bent or dented tubes, etc) should be


CHAPTER 2 replaced.
Pressure Vessel Assembly

1. Preparation for Assembly . . . . . . . . . . . . . 2-1 CAUTION


2. Position the Base . . . . . . . . . . . . . . . . . . . 2-3
3. Level the Base . . . . . . . . . . . . . . . . . . . . . 2-3
4. Positioning the Lower Drum on the Base . . . 2-3 Drum tube holes may have sharp edges from
5. Upper Drum Placement . . . . . . . . . . . . . . 2-4 the machining processes. In order to prevent
6. Check All Drum Holes and Studs . . . . . . . . 2-4 cuts or serious personal injury, gloves should
7. Tube Installation . . . . . . . . . . . . . . . . . . . 2-6 be worn when cleaning.
8. Ferrule Retainers . . . . . . . . . . . . . . . . . . 2-14
9. Pass Seals . . . . . . . . . . . . . . . . . . . . . . . . 2-5
10. Installation of Pressure Vessel to Base . . 2-16
11. Pressurized Leak Test . . . . . . . . . . . . . . 2-16
The ferrule joint must be clean and free of oil and
1. Preparation for Assembly debris in order to protect the lubricating and sealing
properties of the ferrule joint and sealant.
The Model FLE boiler uses eleven separate tube
patterns that provide the gas passages for the five
pass gas-flow configuration. One member of the
assembly team should be designated to assure that
the proper tube is selected for each tube position. WARNING
Before beginning assembly of the pressure vessel
the required component parts should be brought to If overhead lifting points are used to suspend
the work area and organized. The time required to or move the boiler components during
assemble the pressure vessel will be affected by the assembly, care must be taken to ensure that
ease with which the correct part can be located, and the lifting points and the lifting devices are
by the proximity of the parts storage to the work adequate to support the weight of the
area. components being lifted. Failure to follow this
warning may result in serious personal injury
All joined fittings, whether they are driven ferrules or or death.
bolted flanges, should be inspected for any shipping
damage prior to assembly. The surfaces of the tube
holes in the drum and tube ferrule must be free of
dirt, protective coatings, corrosion, or physical
damage. Care must be taken in handling boiler
tubes during assembly to prevent damage to the
ferrules.
Slight damage to the drum tube holes or to the tube
ferrules (such as scratches or light surface corrosion)
should be repaired with fine (150 grit or finer)
emery cloth. Pressure vessel components with
significant damage (corrosion pitting of sealing

750-192 2-1
Pressure Vessel Assembly Model FLE Assembly

Figure 2-1. Completed Pressure Vessels; Steam (left) and Hot Water (right)

Table 2- 1: Center-to-Center and Drum Length Dimensions

Model Dimension (in) Drum Length End to


Centerline to Centerline End
Steam Hot Water Steam Hot Water
150 60 56-1/2 98 98-3/8
200 60 56-1/2 98 98-3/8
250 60 56-1/2 98 98-3/8
300 64 60-1/2 104 104-3/8
350 64 60-1/2 104 104-3/8
400 67 63-1/2 126 126-3/8
450 67 63-1/2 126 126-3/8
500 67 63-1/2 126 126-3/8
550 67 63-1/2 126 126-3/8
600 67 63-1/2 126 126-3/8
700 77 69-1/2 150 147
800 77 69-1/2 150 147
900 77 69-1/2 150 147
1000 77 69-1/2 182 172-1/2
1100 77 69-1/2 182 172-1/2
1200 77 69-1/2 182 172-1/2

2-2 750-192
Model FLE Assembly Pressure Vessel Assembly

2. Position the Base

3 layers of
insulation
under lower
drum, front
and rear

Figure 2-2. Placing lower drum on base


Move the base into position with lifting straps, pry Figure 2-3. Front (left) and Rear (right) of the base
bars and winching equipment. The front side of the
base sits on the same side as the burner and has a
smaller distance between the front edge of the base
and the angle brackets holding the refractory. The
rear of the base has more space to accommodate
the thicker insulation in the rear wall (Figure 2-3).

3. Level the Base


Using shims (not provided), level the base. Start
with the front and rear sections (leveling it side to
side), followed by the side sections.

4. Positioning the Lower Drum on Figure 2-4. Bolting upper drum to downcomers
the Base
Cut the base strip into three equal pieces. Layer
them on the base between the refractory and drum
support. The 5” wide strip is for the front and the 7”
for the rear.
Position the lower drum on the base and place one
bolt on both the front and the rear. Once this is
finished, secure the four bolts on the rear, then the
four bolts on the front.

NOTE: Whenever bolts are used, apply Figure 2-5. Continually check level as vessel is
“Never Seez”. Hand tighten the bolts being assembled
and when everything is in the desired
position, tighten completely. This pro-
cedure is to be used for ALL bolts.

750-192 2-3
Pressure Vessel Assembly Model FLE Assembly

5. Upper Drum Placement Studs


Using appropriately sized lifting devices, place the If there are any threads causing the tube retainer
upper drum in position above the downcomer and studs to bind, chase them with a 5/8” die (Figure 2-
lower drum. Apply sealant to the downcomer gasket 8). Checking all the retainer stud threads will make
and position the gasket between the flanges. Using the assembly process go smoother. All retainer
the studs provided, secure the flanges and/or front studs must be coated with “Never-Seez”.
spreader bar. Apply “Never-Seez” to all flange studs.
This will establish the correct distance between the
drums at the front of a steam boiler and the rear of
both steam and hot water boilers. The correct drum-
to-drum spacing at the front of the boiler is
established by temporarily installing an adjustable
drum spreader. The drum spreader should be
installed at the end of the drums, as shown in
Figure 2-6. The part numbers for the drum
spreaders are shown in Table 2-2. See table 2-1 for
drum dimensions.

Table 2-2 Drum Spreader Part Numbers for Hot Wa-


ter Units by Size
Size Part No.
150-250 98-317
300-350 98-323
400-600 98-318
700-1200 98-324

6. Check All Drum Holes and Studs Figure 2-6. Drum spreader in position on completed
vessel
Drum Holes
Check all drum holes for any burrs, weld splatter or
distortion as any imperfections must be cleaned or
repaired. To clean burrs or welding spatter, use 150
grit emery cloth (Figure 2-7).

CAUTION

Drum holes may be sharp from the machining


process. Burrs and sharp machined edges can
cause severe cuts. Care must be taken when
inspecting drum holes.
Figure 2-7. Use a 5/8" die to chase all the retainer
stud threads

2-4 750-192
Model FLE Assembly Pressure Vessel Assembly

The pressure vessel is assembled in the factory,


hydro tested and stamped (Figure 2-9). For
convenient assembly, prior to disassembly and
crating, all the tubes are color coded and numbered
with the corresponding numbers on the drums. In
the process of staging the components for assembly,
there could be circumstances where the individual
tubes have to be hand carried to the assembly site.
If the assemblers are unsure of the correct tube
placement, verify the correct location for each tube
by measuring the second, third or forth pass gap
and cross reference with tube location figures in this
chapter.

Figure 2-8. Use caution when inspecting drum holes

Figure 2-9. A steam vessel (left) and a hot water vessel (right)

750-192 2-5
Pressure Vessel Assembly Model FLE Assembly

7. Tube Installation Tube installation should begin at the rear of the


pressure vessel, in order to take advantage of the
Tubes are formed in eleven different patterns in
rigidity provided by the downcomer pipe. The
order to provide a five-pass gas flow path through
pressure vessel will become progressively more rigid
the boiler (Figure 2-10). Tubes can be identified by
as additional tubes are installed.
visually comparing the tube profile to those shown
in Figures 2-17 and 2-18. Refer to pages 2-9 through 2-13 to determine the
top and bottom of the tubes. Install all of the tubes
Figures 2-19, 2-20 and 2-21 show the proper on one side of the boiler.
location for each tube pattern at the left and right
Install the inner row left-side tube before the outer
sides of the pressure vessel assembly. Tube
row tube. Install the tubes in sequential order. Begin
locations are the same for steam and hot water
installation of the left side tubes with a PATTERN 4
units. The number at each pressure vessel tube
tube installed in the second to last position in the
location in Figures 2-19, 2-20 and 2-21 refers to
upper drum (last tube hole in the bottom drum).
the tube pattern numbers shown in Figures 2-17
Install the vent tube PATTERN 3 next, followed by
and 2-18.
the remaining left side tubes.

Table 2- 3: Inner and Outer Tube Patterns


INNER ROW TUBES OUTER ROW TUBES
Tube Pattern 4 Tube Pattern 1
Tube Pattern 5 Tube Pattern 2
Tube Pattern 9 Tube Pattern 3
Tube Pattern 10 Tube Pattern 6
Tube Pattern 11 Tube Pattern 7
Tube Pattern 8
See note below Tube ferrule and drum socket surfaces must be free
of any dirt, corrosion, or petroleum-based lubricants
in order to ensure that the tube ferrule and sealant
work effectively
Tubes are driven into place with a tube driving tool,
(Figure 2-11) which is seated against a raised
shoulder on the tube ferrules. A 16-pound
Figure 2-10. Cross section showing tubes forming
the five gas passes sledgehammer is recommended for driving the
tubes.
Note: The horizontal tubes between the first
and second pass with a gap greater than 3/32”
must be packed with ceramic insulation. WARNING
One member of the assembly team should become Heavy-duty work gloves and hearing and eye
familiar with the boiler’s tube patterns and keep protection must be worn by assemblers when
track of the tubes as they are installed. driving boiler tubes. Failure to heed this
warning may result in damage to the eyes,
Inspect the tube ferrules for flat spots or scuffs due hearing impairment, or serious personal
injury.
to shipping. Repair or replace any tube that may
have been damaged during shipment

2-6 750-192
Model FLE Assembly Pressure Vessel Assembly

Use a modified vice-grip clamp to secure the driving To achieve a tight fit between tubes, drive the tubes
tool to the ferrule. to a uniform depth.
Install the remaining tubes on the right side, follow-
Before installing the tubes, apply a thin, uniform ing the proper tube pattern sequence as shown in
coat of Lock-Tite sealant (Part Number 872-716) to Figure 2-19, 2-20 and 2-21.
the first 1/2” of the ferrule and the drum socket
surfaces.
Both ends of the tube should be inserted into the
drum holes before the tubes are driven into place.
The driving tool must be securely held in place
against the tubes during the driving operation with
vice-grip type clamps (Figure 2-14).
Ferrules must be driven in to expose only 3/4 inch of
the tapered portion of the ferrule.

CAUTION - The tube driving tool must be securely Figure 2-11. Tube Driving tools and Tube Removal
held against the tube during the driving operation. Tool
Failure to do so is likely to result in damage to the
driving surfaces of the tube ferrule and the tube
driving tool.

The orientation of the first tube installed to the


drums will affect the location of all of the following
tubes. Check that the drums are level using a
bubble level. With the first tube loosely installed in
the drum sockets, place the bubble level against the
tube and adjust the orientation of the tube so that it
is perpendicular to the drums. When the orientation
of the tube is correct, drive them into the drums.
The tube ferrules must be correctly aligned with the
tube sockets when the tubes are being driven into Figure 2-12. Driving lower end of first tube
place in the drums. Although the taper on the
mating surfaces of the tube ferrule and tube hole
provide for alignment of the tube, misalignment
(cocking) may occur and is likely the cause of a tube
becoming difficult to drive before the required depth
of insertion is reached. In this case, remove the
tube, check the ferrule and socket surfaces for
damage and repair or replace it if necessary.
Reapply Lock-Tite® sealant to the ferrule and
socket surfaces, and reinsert the tube ends in the
drum sockets. After checking the tube alignment,
drive the tube ferrules into place with the difficult
ferrule first.

750-192 2-7
Pressure Vessel Assembly Model FLE Assembly

Figure 2-13. Both ends of the tube must be inserted


prior to driving the tubes

Figure 2-15. Tubes driven to uniform depth

Figure 2-14. Use a modified vice-grip to hold driving


tool tight to the tube

Figure 2-16. Completed Pressure Vessel

2-8 750-192
TUBE PATTERNS, STEAM
750-192

1 2 3 4 5 6 7 8 9

BOILER SIZE 150-250 300-350 400-600 700-1200


P/N TUBE # 1 93-3200 93-3211 93-3222 93-3233
P/N TUBE # 2 93-3201 93-3212 93-3223 93-3234
P/N TUBE # 3 93-3202 93-3213 93-3224 93-3235
P/N TUBE # 4 93-3203 93-3214 93-3225 93-3236
P/N TUBE # 5 93-3204 93-3215 93-3226 93-3237
P/N TUBE # 6 93-3205 93-3216 93-3227 93-3238
P/N TUBE # 7 93-3206 93-3217 93-3228 93-3239
P/N TUBE # 8 93-3207 93-3218 93-3229 93-3240
P/N TUBE # 9 93-3208 93-3219 93-3230 93-3241
P/N TUBE # 10 93-3209 93-3220 93-3231 93-3242
10 11 P/N TUBE # 11 93-3210 93-3221 93-3232 93-3243
Figure 2-18. Tube Patterns - Steam
2-9
2-10

TUBE PATTERNS, HOT WATER

1 2 3 4 5 6 7 8 9

BOILER SIZE 150-250 300-350 400-600 700-1200


P/N TUBE #1 93-2685 93-2696 93-2707 93-2718
P/N TUBE #2 93-2686 93-2697 93-2708 93-2719
P/N TUBE #3 93-2687 93-2698 93-2709 93-2720
P/N TUBE #4 93-2688 93-2699 93-2710 93-2721
P/N TUBE #5 93-2689 93-2700 93-2711 93-2722
P/N TUBE #6 93-2690 93-2701 93-2712 93-2723
P/N TUBE #7 93-2691 93-2702 93-2713 93-2724
P/N TUBE #8 93-2692 93-2703 93-2714 93-2725
10 11 P/N TUBE #9 93-2693 93-2704 93-2715 93-2726
P/N TUBE #10 93-2694 93-2705 93-2716 93-2727
P/N TUBE #11 93-2695 93-2706 93-2717 93-2728
Figure 2-17. Tube Patterns - Hot Water
750-192
750-192

STEAM
Boiler Sizes 150-250 300-350 400-600
Assembly Part No. 93-3244 93-3245 93-3246
ITEM DESCRIPTION REQ PART NO REQ PART NO REQ PART NO
1 TUBE PATTERN, NO. 1 3 93-3200 3 93-9211 3 93-3222
2 TUBE PATTERN, NO. 2 15 93-3201 17 93-9212 24 93-3223
3 TUBE PATTERN, NO. 3 1 93-3202 1 93-9213 1 93-3224
4 TUBE PATTERN, NO. 4 3 93-3203 3 93-9214 3 93-3225
5 TUBE PATTERN, NO. 5 15 93-3204 17 93-9215 24 93-3226
6 TUBE PATTERN, NO. 6 2 93-3205 2 93-9216 2 93-3227
7 TUBE PATTERN, NO. 7 15 93-3206 17 93-9217 24 93-3228
8 TUBE PATTERN, NO. 8 2 93-3207 2 93-9218 2 93-3229
9 TUBE PATTERN, NO. 9 1 93-3208 1 93-9219 1 93-3230
10 TUBE PATTERN, NO. 10 15 93-3209 17 93-9220 24 93-3231
11 TUBE PATTERN, NO. 11 2 93-3210 2 93-9221 2 93-3232

HOT WATER
Boiler Sizes 150-250 300-350 400-600
Assembly Part No. 93-2729 93-2737 93-2738
ITEM DESCRIPTION REQ PART NO REQ PART NO REQ PART NO
1 TUBE PATTERN, NO. 1 3 93-2685 3 93-2696 3 93-2707
2 TUBE PATTERN, NO. 2 15 93-2686 17 93-2697 24 93-2708
3 TUBE PATTERN, NO. 3 1 93-2687 1 93-2698 1 93-2709
4 TUBE PATTERN, NO. 4 3 93-2688 3 93-2699 3 93-2710
5 TUBE PATTERN, NO. 5 15 93-2689 17 93-2700 24 93-2711
6 TUBE PATTERN, NO. 6 2 93-2690 2 93-2701 2 93-2712
7 TUBE PATTERN, NO. 7 15 93-2691 17 93-2702 24 93-2713
8 TUBE PATTERN, NO. 8 2 93-2692 2 93-2703 2 93-2714
9 TUBE PATTERN, NO. 9 1 93-2693 1 93-2704 1 93-2715
10 TUBE PATTERN, NO. 10 15 93-2694 17 93-2705 24 93-2716
11 TUBE PATTERN, NO. 11 2 93-2695 2 93-2706 2 93-2717
Figure 2-19. Tube Arrangement, Boiler Sizes 150 to 600
2-11
STEAM
750-192

Boiler Sizes 700-900


Assembly Part No. 93-3247
ITEM DESCRIPTION REQ PART NO
1 TUBE PATTERN, NO. 1 4 93-3233
2 TUBE PATTERN, NO. 2 30 93-3234
3 TUBE PATTERN, NO. 3 1 93-3235
4 TUBE PATTERN, NO. 4 4 93-3236
5 TUBE PATTERN, NO. 5 30 93-3237
6 TUBE PATTERN, NO. 6 2 93-3238
7 TUBE PATTERN, NO. 7 30 93-3239
8 TUBE PATTERN, NO. 8 3 93-3240
9 TUBE PATTERN, NO. 9 2 93-3241
10 TUBE PATTERN, NO. 10 30 93-3242
11 TUBE PATTERN, NO. 11 2 93-3243

HOT WATER
Boiler Sizes 700-900
Assembly Part No. 93-2730
ITEM DESCRIPTION REQ PART NO
1 TUBE PATTERN, NO. 1 4 93-2718
2 TUBE PATTERN, NO. 2 30 93-2719
3 TUBE PATTERN, NO. 3 1 93-2720
4 TUBE PATTERN, NO. 4 4 93-2721
5 TUBE PATTERN, NO. 5 30 93-2722
6 TUBE PATTERN, NO. 6 2 93-2723
7 TUBE PATTERN, NO. 7 30 93-2724
8 TUBE PATTERN, NO. 8 3 93-2725
9 TUBE PATTERN, NO. 9 2 93-2726
10 TUBE PATTERN, NO. 10 30 93-2727
11 TUBE PATTERN, NO. 11 2 93-2728
Figure 2-20. Tube Arrangement, Boiler Sizes 700 to 900
2-12
STEAM
750-192

Boiler Sizes 1000-1200


Assembly Part No. 93-3598
ITEM DESCRIPTION REQ PART NO
1 TUBE PATTERN, NO. 1 6 93-3233
2 TUBE PATTERN, NO. 2 36 93-3234
3 TUBE PATTERN, NO. 3 1 93-3235
4 TUBE PATTERN, NO. 4 6 93-3236
5 TUBE PATTERN, NO. 5 36 93-3237
6 TUBE PATTERN, NO. 6 3 93-3238
7 TUBE PATTERN, NO. 7 36 93-3239
8 TUBE PATTERN, NO. 8 4 93-3240
9 TUBE PATTERN, NO. 9 3 93-3241
10 TUBE PATTERN, NO. 10 36 93-3242
11 TUBE PATTERN, NO. 11 3 93-3243

HOT WATER
Boiler Sizes 1000-1200
Assembly Part No. 93-3599
ITEM DESCRIPTION REQ PART NO
1 TUBE PATTERN, NO. 1 6 93-2718
2 TUBE PATTERN, NO. 2 36 93-2719
3 TUBE PATTERN, NO. 3 1 93-2720
4 TUBE PATTERN, NO. 4 6 93-2721
5 TUBE PATTERN, NO. 5 36 93-2722
6 TUBE PATTERN, NO. 6 3 93-2723
7 TUBE PATTERN, NO. 7 36 93-2724
8 TUBE PATTERN, NO. 8 4 93-2725
9 TUBE PATTERN, NO. 9 3 93-2726
10 TUBE PATTERN, NO. 10 36 93-2727
11 TUBE PATTERN, NO. 11 3 93-2728
Figure 2-21. Tube Arrangement, Boiler Sizes 1000 to 1200
2-13
Pressure Vessel Assembly Model FLE Assembly

CAUTION - Ferrule Retainers must be


installed as the tubes are being inserted.
Failure to do so can lead to the tubes popping
out.

Figure 2-22. Ferrules must be driven in to expose


only 3/4 inch of the tapered portion of the ferrule

8. Ferrule Retainers
Tube ferrule retainers are provided to ensure Figure 2-23. Rainier on the shoulder of a group of
three ferrules
retention of the tubes and to prevent outward
movement of the tube ferrules as a result of
expansion and contraction during operation. The
retainers should be installed as the tubes are being
driven into the drums. When the first three tubes
have been inserted, secure the retainer before
inserting any more tubes.

Note: The ferrule retainers for the top and the


bottom are different.

Each retainer (except for the vent tube retainer and


end tubes) applies force upon several adjacent tube Figure 2-24. Installing retainer on ferrule shoulders
ferrules. The retainers must be positioned so the
force is uniformly distributed on the driving surfaces
of the tube ferrules (see Figure 2-23 to 2-25)

WARNING - If overhead lifting points are used


to suspend or move the boiler components
during assembly, care must be taken to
ensure that the lifting points and the lifting
devices used are adequate to support the
weight of the components being carried.
Failure to heed this warning may result in
damage to the equipment or serious personal
injury or death. Figure 2-25. Vent tube retainer (with welded tab)

2-14 750-192
Model FLE Assembly Pressure Vessel Assembly

9. Pass Seals
Two lengths of ceramic fiber insulation seal the
sides of the upper gas passes. The pass seals are
installed between the contact areas of the left and
right side tubes as shown in Figure 2-26. The seals
are compressed and held in place as the left side
tubes are driven into place. Cut the seals from the
supplied bulk material. Use a spray glue to hold the
insulation in place while installing the left side
tubes.
Figure 2-26. Install pass seals before installing left
side tubes
WARNING

Gloves and an appropriate respirator should


be worn when handling or working with
insulating materials. Handling or working with
insulating materials may result in skin
irritation or may pose a health risk from
inhaling insulation fibers.

Proceed with tube installation in the same manner


as with the previously installed right-side tubes,
following the proper tube pattern sequence for the Figure 2-27. Upper pass seal installed
right-side tubes as shown in Figures 2-19, 2-20 and
2-21.

CAUTION

Model FLE boilers are equipped with two


lifting lugs located on the upper drum. The
lugs should be used to lift or to pull the boiler.
If the vessel is a Hot Water unit, be sure the
front spreader is securely bolted in place prior Figure 2-28. Lower pass seal installed
to lifting or moving the unit. Do not lift or move
the boiler by pushing, prying, or pulling on the
tubes, or downcomer pipe. Failure to follow
these instructions could result in equipment
damage.

750-192 2-15
Pressure Vessel Assembly Model FLE Assembly

10. Installation of Pressure Vessel to the retainer plate and drive the ferrule deeper into
Base the drum. Drive the ferrule only far enough to
eliminate leakage.
If the pressure vessel has been built on stands or is
Table 2- 2: Recommended Pressure for Leak Test
suspended, follow the earlier procedures for
Boiler Design Recommended
mounting and securing the pressure vessel to the
Pressure for Leak Test
base. 15 psi Steam 15 psi
150 psi Steam 150 psi
160 psi Hot Water 160 psi

A leak test requires that the following must be


attended to:
• Connection points to the pressure vessel must be
blocked with blind flanges, plugs, or caps
capable of withstanding the required test
pressure.
• A valve capable of withstanding the required test
pressure must be installed in the vent fitting at the
top of the pressure vessel.
• A source of clean water with a minimum
temperature of 70°F must be available to fill the
Figure 2- 29: Leak testing the completed pressure pressure vessel.
vessel to the boiler design pressure

CAUTION -
Before resealing the
WARNING - The assembled Model FLE
ferrules, relieve pressure from the vessel.
pressure vessel is heavy. Until the pressure Once the ferrules are resealed, repeat the
vessel is secured to the base, it will be pressurized leak test.
unstable when standing in an upright position.
Failure to adequately and properly restrain
and/or suspend the drum and tube assembly
prior to securing it to the base may allow the
assembly to fall with the possibility of causing
serious personal injury or death

11. Pressurized Leak Test


After the pressure vessel has been assembled, a
leak test must be performed. The leak test takes as
much time as is needed to check that there are no
leaks. The assembler is responsible for arranging
and preparing for the leak test. An air compressor
capable of pressurizing the flooded pressure vessel
to its design pressure will be required.
If any ferrule-to-drum joint leaks are apparent, the
affected ferrule will need to be driven deeper into Figure 2-29. With the vessel flooded and
pressurized, check for leaks at all ferrules and
the drum. Relieve the hydraulic pressure, remove
flanges

2-16 750-192
Model FLE Assembly Casing Assembly

CHAPTER 3
CAUTION
FLE Casing Assembly
Procedures Model FLE casing panels are shipped with
insulation attached. Care must be taken when
1. Install Wetpack around Vent Tube . . . . . . . 3-8 handling casing panels In order to prevent
2. Install Backing Plates . . . . . . . . . . . . . . . . 3-8 damage to the insulating materials.
3. Install Rear Wall Sections . . . . . . . . . . . . . 3-9
4. Drill Rear Sight Port . . . . . . . . . . . . . . . 3-12
5. Wetpack Installation Around Lower Drum . 3-14 CAUTION
6. Finish Installing Backing Plates . . . . . . . . 3-14
7. Install Front Wall Section . . . . . . . . . . . . 3-14
8. Install Roof Panel . . . . . . . . . . . . . . . . . . 3-14 Careful attention must be given to the
9. Install Burner Door . . . . . . . . . . . . . . . . 3-16 placement and integrity of casing joint gaskets
10. Install Lift Lug Cover . . . . . . . . . . . . . . . 3-17 and seals during assembly to ensure a tight
11. Install Drum Packing and Seal Plates . . . 3-18 seal. All casing joints must be completely
12. Install Insulation Under Tubes . . . . . . . . 3-19
sealed against leakage of combustion gases.
13. Install Pass Insulation . . . . . . . . . . . . . . 3-19
Failure to ensure a tight seal at the joints may
14. Prepare for Inner Casing Installation . . . . 3-20
15. Prepare Inner Panels for Installation . . . 3-21 result in leakage of combustion gases and will
14. Install Inner Casing . . . . . . . . . . . . . . . . 3-22 cause damage to adjacent areas of the casing
17. Install Outer Casing . . . . . . . . . . . . . . . 3-23 panels during operation of the boiler.

The casing of the Model FLE Boiler encloses and


forms a shell around the pressure vessel. Casing
panels are bolted together and can be removed for
inspection and servicing of the internal boiler
components. Casing panels must be installed and
fastened together in a specific order to ensure a
strong seal.
Casing panels are joined by bolts or studs and are
sealed by an expanded PTFE gasket material.
In addition to applying the gasket, a small amount
of Teflon paste and high temperature sealant,
supplied with the Model FLE assembly kit, is to be
applied to the indicated areas before the panels are
installed.

750-192 3-1
3-2

Figure 3-1. Typical Hot Water Flextube Casing


750-192
750-192

Part List, Hot Water 250 350 500 800 1100


ITEM DESCRIPTION PART # PART # REQ PART # REQ PART # REQ PART # REQ
REQ
1. Base 315-1124 1 315-1169 1 315-1180 1 315-1194 1 315-1203 1
2. Roof 315-1127 1 315-1167 1 315-1178 1 315-1192 1 315-1202 1
3.a Front wall, w/o Hinge 315-1262 1 315-1265 1 n/a n/a n/a
3.b Front wall w Hinge 315-1128 1 315-1166 1 315-1177 1 315-1191 1 315-1201 1
4. Rear wall-large piece 315-1129 1 315-1165 1 315-1176 1 315-1190 1 315-1190 1
5. Outer casing panel 315-1130 6 315-1164 6 315-1175 8 315-1189 10 315-1198 12
6. Outer casing strips-top 315-1131 2 315-1163 2 315-1174 2 315-1188 2 315-1197 4
7. Plate, base to wall 315-1132 4 315-1132 4 315-1132 4 315-1132 4 315-1132 4
8. Outer casing strips corner strip 315-1133 4 315-1162 4 315-1173 4 315-1187 4 315-1187 4
9. Burner plate Note 5 1 Note 5 1 Note 5 1 Note 5 1 Note 5 1
10. Inner side panel Left Hand 315-1135 2 315-1161 2 315-1172 2 315-1186 2 315-1196 2
11. Inner side panel Right Hand 315-1136 2 315-1160 2 315-1171 2 315-1185 2 315-1195 2
12. Mounting Plate 315-1143 1 315-1143 1 315-1143 1 315-1143 1 315-1143 1
13. Plate, Collar, Lower Outer 315-694 2 315-694 2 315-695 2 315-695 2 315-695 2
14. Plate, Collar, Upper Outer 315-1159 2 315-1159 2 315-1183 2 315-1183 4 315-1210 2
15. Plate, Cover, Lug, Lifting 315-1100 1 315-1100 1 315-1100 1 315-1099 1 315-1099 1
16. Cap, sight 550-42 1 550-42 1 550-42 1 550-42 1 550-42 1
17. Capscrew, hex hd. 3/8”-16x 3/4”lg 868-1506 26 868-1506 28 868-1506 60 868-1506 96 868-1506 128
18. Capscrew, hex hd. 1/2”-13x 1-1/2”lg 868-102 8 868-102 8 868-102 8 868-102 8 868-102 8
19. Capscrew, hex hd. 5/8”-11x 1-1/2”lg 868-188 8 868-188 8 868-188 8 868-188 8 868-188 8
20. Screw, self tapping, ¼” x 1”lg 841-423 50 841-423 50 841-423 50 841-423 50 841-423 54
21. Locknut, hex hd., 3/8” 869-510 118 869-510 124 869-510 180 869-510 232 869-510 284
22. Nut, hex hd., ½” brass 869-27 12 869-27 12 869-27 12 869-27 12 869-27 12
23. Nut, hex hd., ½” 869-144 24 869-144 24 869-144 24 869-144 28 869-144 28
24. Capscrew, Hex hd ¾”-10 x 6” LG 868-600 2 868-600 2 868-600 2 868-600 2 868-600 2
25. Washer, flat, ½” 952-286 44 952-286 44 952-286 44 952-286 48 952-286 48
26. Washer, flat, 5/8” 952-321 8 952-321 8 952-321 8 952-321 8 952-321 8
27. Never-Seez 797-1816 1 797-1816 1 797-1816 1 797-1816 1 797-1816 1
28. Inner Casing Spacer Block 315-1336 8 315-1336 8 315-1336 12 315-1336 16 315-1336 20
29. Inner Side Panel Mid Left n/a n/a n/a 315-1294 2 315-1294 2
30. Inner Side Panel Mid Right n/a n/a n/a 315-1208 2 315-1208 2
31. Inner Side Panel Mid n/a n/a 315-1206 2 n/a 315-1209 2
32. Retaining Plates, Lower, Inner, Small 315-1178 3 315-1178 3 315-1280 3 315-1280 3 315-1280 3
33. Retaining Plates, Lower, Inner, Large 315-1158 1 315-1158 1 315-1182 1 315-1182 1 315-1182 1
34. Plate, collar, upper, inner 315-1204 2 315-1204 2 315-1207 2 n/a 315-1183 2
35. Assembly, rear wall corner piece 315-1140 1 315-1279 1 315-1281 1 315-1282 1 315-1282 1
36. Gasket, Expanded PTFE 3/8” x 3/16” 32-2560 70 ft 32-2560 75 ft 32-2560 99 ft 32-2560 127ft 32-2560 149ft
37. Handle, Flush Mount, Snap In 865-68 12 865-68 12 865-68 16 865-68 16 865-68 24
3-3
3-4

Figure 3-2. Typical Low Pressure Steam Flextube Casing


750-192
750-192

Part List, LP Steam 250 350 500 800 1100


PART PART PART
ITEM DESCRIPTION PART # REQ REQ PART NO. REQ REQ
REQ NO. NO, NO.
1. Base 315-1124 1 315-1169 1 315-1180 1 315-1194 1 315-1203 1
2. Roof 315-1215 1 315-1230 1 315-1239 1 315-1250 1 315-1260 1
3.a Front wall, w/o Hinge 315-1263 1 315-1264 1 n/a n/a n/a
3.b Front wall w Hinge 315-1216 1 315-1229 1 315-1138 1 315-1249 1 315-1249 1
4. Rear wall-large piece 315-1217 1 315-1228 1 315-1237 1 315-1248 1 315-1248 1
5. Outer casing panel 315-1218 6 315-1227 6 315-1236 8 315-1247 10 315-1257 12
6. Outer casing strips-top 315-1131 2 315-1163 2 315-1174 2 315-1188 2 315-1197 4
7. Plate, base to wall 315-1132 4 315-1132 4 315-1132 4 315-1132 4 315-1132 4
8. Outer casing strips corner strip 315-1219 4 315-1226 4 315-1235 4 315-1246 4 315-1246 4
9. Burner plate Note 5 1 Note 5 1 Note 5 1 Note 5 1 Note 5 1
10. Inner side panel Left Hand 315-1220 2 315-1225 2 315-1234 2 315-1245 2 315-1256 2
11. Inner side panel Right Hand 315-1221 2 315-1224 2 315-1233 2 315-1244 2 315-1255 2
12. Mounting Plate 315-1143 1 315-1143 2 315-1143 2 315-1143 2 315-1143 2
13. Plate, Collar, Lower Outer 315-694 2 315-694 2 315-695 2 315-695 2 315-695 2
14. Plate, Collar, Upper Outer 315-1222 2 315-1222 2 315-1222 2 315-1243 2 315-1243 2
15. Plate, Cover, Lug, Lifting 315-1100 1 315-1100 1 315-1100 1 315-1099 1 315-1099 1
16. Cap, sight 550-42 1 550-42 1 550-42 1 550-42 1 550-42 1
17. Capscrew, hex hd. 3/8”-16x 3/4”lg 868-1506 28 868-1506 30 868-1506 64 868-1506 108 868-1506 144
18. Capscrew, hex hd. 1/2”-13x 1-1/2”lg 868-102 8 868-102 8 868-102 8 868-102 8 868-102 8
19. Capscrew, hex hd. 5/8”-11x 1-1/2”lg 868-188 8 868-188 8 868-188 8 868-188 8 868-188 8
20. Screw, self tapping, ¼” x 1”lg 841-423 56 841-423 56 841-423 56 841-423 56 841-423 60
21. Locknut, hex hd., 3/8” 869-510 128 869-510 130 869-510 188 869-510 252 869-510 308
22. Nut, hex hd., ½” brass 869-27 12 869-27 12 869-27 12 869-27 12 869-27 12
23. Nut, hex hd., ½” 869-144 28 869-144 28 869-144 28 869-144 32 869-144 32
24. Capscrew, Hex hd ¾”-10 x 6” LG 868-600 2 868-600 2 868-600 2 868-600 2 868-600 2
25. Washer, flat, ½” 952-286 48 952-286 48 952-286 48 952-286 52 952-286 52
26. Washer, flat, 5/8” 952-321 8 952-321 8 952-321 8 952-321 8 952-321 8
27. Never-Seez 797-1816 1 797-1816 1 797-1816 1 797-1816 1 797-1816 1
28. Inner Casing Spacer Block 315-1336 8 315-1336 8 315-1336 12 315-1336 16 315-1336 20
29. Inner Side Panel Mid Left n/a n/a n/a 315-1295 2 315-1295 2
30. Inner Side Panel Mid Right n/a n/a n/a 315-1253 2 315-1253 2
31. Inner Side Panel Mid n/a n/a 315-1242 2 n/a 315-1261 2
32. Retaining Plates, Lower, Inner, Small 315-1278 3 315-1278 3 315-1280 3 315-1280 3 315-1280 3
33. Retaining Plates, Lower, Inner, Large 315-1158 1 315-1158 1 315-1282 1 315-1182 1 315-1182 1
34. Plate, collar, upper, inner 315-1223 2 315-1223 2 315-1223 2 351-1254 1 315-1254 2
35. Ring Seal, Outlet Steam #15 315-219 1 315-220 1 315-221 1 315-1057 1 315-1058 1
36. Assembly, rear wall corner piece 315-1286 1 315-1287 1 315-1289 1 315-1291 1 315-1291 1
37. Assembly, front wall corner piece 315-1285 1 315-1288 1 315-1290 1 315-1292 1 315-1292 1
38. Gasket, Expanded PTFE 3/8” x 3/16” 32-2560 79 ft 32-2560 86 ft 32-2560 110 ft 32-2560 144ft 32-2560 168ft
39. Handle, Flush Mount, Snap In 865-68 12 865-68 12 865-68 16 865-68 20 865-68 24
3-5
3-6

Figure 3-3. Typical High Pressure Steam Flextube Casing


750-192
750-192

Parts List, HP Steam 250 350 500 800 1100


ITEM DESCRIPTION PART # REQ PART # REQ PART # REQ PART # REQ PART # REQ
1. Base 315-1124 1 315-1169 1 315-1180 1 315-1194 1 315-1203 1
2. Roof 315-1215 1 315-1230 1 315-1239 1 315-1250 1 315-1260 1
3.a Front wall w/o Hinge 315-1263 1 315-1264 1 n/a n/a n/a
3.b Front wall w Hinge 315-1216 1 315-1229 1 315-1238 1 315-1249 1 315-1249 1
4. Rear wall-large piece 315-1217 1 315-1228 1 315-1237 1 315-1248 1 315-1248 1
5. Outer casing panel 315-1218 6 315-1227 6 315-1236 8 315-1247 10 315-1257 12
6. Outer casing strips-top 315-1131 2 315-1163 2 315-1174 2 315-1188 2 315-1197 4
7. Plate, base to wall 315-1132 4 315-1132 4 315-1132 4 315-1132 4 315-1132 4
8. Outer casing strips corner strip 315-1219 4 315-1226 4 315-1235 4 315-1246 4 315-1246 4
9. Burner plate Note 5 1 Note 5 1 Note 5 1 Note 5 1 Note 5 1
10. Inner side panel Left Hand 315-1220 2 315-1225 2 315-1234 2 315-1245 2 315-1256 2
11. Inner side panel Right Hand 315-1221 2 315-1224 2 315-1233 2 315-1244 2 315-1255 2
12. Mounting Plate 315-1143 2 315-1143 2 315-1143 2 315-1143 2 315-1143 2
13. Plate, Collar, Lower Outer 315-694 2 315-694 2 315-695 2 315-695 2 315-695 2
14. Plate, Collar, Upper Outer 315-1222 2 315-1222 2 315-1222 2 315-1243 2 315-1243 2
15. Plate, Cover, Lug, Lifting 315-1100 1 315-1100 1 315-1100 1 315-1099 1 315-1099 1
16. Cap, sight 550-42 1 550-42 1 550-42 1 550-42 1 550-42 1
17. Capscrew, hex hd. 3/8”-16x 3/4”lg 868-1506 28 868-1506 30 868-1506 64 868-1506 108 868-1506 144
18. Capscrew, hex hd. 1/2”-13x 1-1/2”lg 868-102 8 868-102 8 868-102 8 868-102 8 868-102 8
19. Capscrew, hex hd. 5/8”-11x 1-1/2”lg 868-188 8 868-188 8 868-188 8 868-188 8 868-188 8
20. Screw, self tapping, ¼” x 1”lg 841-423 50 841-423 56 841-423 56 841-423 56 841-423 60
21. Locknut, hex hd., 3/8” 869-510 118 869-510 130 869-510 188 869-510 252 869-510 308
22. Nut, hex hd., ½” brass 869-27 12 869-27 12 869-27 12 869-27 12 869-27 12
23. Nut, hex hd., ½” 869-144 24 869-144 28 869-144 28 869-144 32 869-144 32
24. Capscrew, Hex hd ¾”-10 x 6” LG 868-600 2 868-600 2 868-600 2 868-600 2 868-600 2
25. Washer, flat, ½” 952-286 44 952-286 48 952-286 48 952-286 52 952-286 52
26. Washer, flat, 5/8” 952-321 8 952-321 8 952-321 8 952-321 8 952-321 8
27. Never-Seez 797-1816 1 797-1816 1 797-1816 1 797-1816 1 797-1816 1
28. Inner Casing Spacer Block 315-1336 8 315-1336 8 315-1336 12 315-1336 16 315-1336 20
29. Inner Side Panel Mid Left n/a 2 n/a n/a 315-1295 2 315-1295 2
30. Inner Side Panel Mid Right n/a 2 n/a n/a 315-1253 2 315-1253 2
31. Inner Side Panel Mid n/a 2 n/a 315-1242 2 n/a 315-1261 2
32. Retaining Plates, Lower, Inner, Small 315-1178 3 315-1278 3 315-1280 3 315-1280 3 315-1280 3
33. Retaining Plates, Lower, Inner, Large 315-1158 1 315-1158 1 315-1282 1 315-1182 1 315-1182 1
34. Plate, collar, upper, inner 315-1223 2 315-1223 2 315-1223 2 315-1254 1 315-1254 2
35. Ring Seal, Outlet Steam #150 315-517 1 315-518 1 315-519 1 315-550 1 315-221 1
36. Assembly, rear wall corner piece 315-1286 1 315-1287 1 315-1289 1 315-1291 1 315-1291 1
37. Assembly, front wall corner piece 315-1285 1 315-1288 1 315-1290 1 315-1292 1 315-1292 1
38. Gasket, Expanded PTFE 3/8” x 3/16” 32-2560 79 ft 32-2560 86 ft 32-2560 110 ft 32-2560 114ft 32-2560 168ft
39. Handle, Flush Mount, Snap In 865-68 12 865-68 12 865-68 16 865-68 16 865-68 16
3-7
Casing Assembly Model FLE Assembly

1. Install Wetpack around Vent Tube


• Position a length of wetpack over the internal portion
of the tube to determine its length. Cut it to fit the
tube then cut a 4” slit at the bottom. Tightly wrap the
tube with the wetpack and tape (with masking or
duct tape) it in place, leaving the slit at the bottom.
Push the wetpack between the adjacent tubes
through the external bend of the vent tube. The joint
should face rear (Figure 3-5).
• Use the remaining piece of insulation (approximately
9” x 9”) and wrap it around the base of the vent
tube, ferrule area and retainer stud Figure 3-6).
• Unfold the wetpack to cover the lower drum and
tubes near the vent tube. Cut a 4 inch slit in the wet-
pack, wrap it around the base of the vent tube and
then unroll it over the lower drum and tubes (Figure
3-7).

Figure 3-4. Location of Vent Tube 2. Install Backing Plates


Remove Support Bracket (Hot Water Units Only)
• Remove the drum spreader
• Torch the support bracket to remove it from the upper
drum. Leave at least ½” of the bracket; if the drum is
cut into, it must go through a long process to ensure
that it can be re-CSA certified, so the easiest way to
prevent this is to leave space between the plate that
is being cut and the drum. DO NOT cut into the
Figure 3-5. Wetpack on vent tube drum.

Upper Backing Plate


• Using wire ties, connect the two pieces of backing
plate together at one point. Place the pieces over the
upper drum (with the tie at the top) and tie the bot-
tom of the two pieces together. Because these plates
stop the insulation from being pushed into the tube
area during packing, the backing plates must be
pushed against the tubes. Make sure that the back-
Figure 3-6. Positioning the 9" x 9" section over the
ing plate seams are in a vertical position around the
ferrules
upper drum (Figure 3-8).

Figure 3-7. Cut a 4 inch slit in the wetpack to cover


the lower drum. Mold the wetpack around the base
of the vent tube. Be sure the vent tube, ferrule and
lower drum are covered.

3-8 750-192
Model FLE Assembly Casing Assembly

Lower Backing Plate

• Install the retaining ring segments on the base


around the lower drum. (Figure 3-9).

Figure 3-8. Installing Backing Plate on Upper Drum

3. Install Rear Wall Sections

• Check that there is gasket positioned on the bottom


of the wall. Apply a continuous bead of silicone
where the end walls will contact the base.
• After checking that the insulation is packed (Figure
3-10), lift the large piece of the rear wall into posi-
tion (Figure 3-11). Until the wall is in the correct ver-
tical position, leave a gap between the tubes and the
wall to keep the insulation from getting squished. Set
the wall section on top of the base.
• Wedge the wall upright.
• Apply “Never-Seez” to the studs and attach the end-
Figure 3-9. Backing Plate on Lower Drum plates to the wall (Figure 3-12).

NOTE: ALWAYS clean mating surfaces


prior to applying silicone caulk. If any
dust, dirt or oil is present, the silicone
will not adhere and will not seal.

Figure 3-10. Packing the Insulation

Figure 3-12. End Plate

Figure 3-11. Placing Wall Section

750-192 3-9
Casing Assembly Model FLE Assembly

1. Install and snug up the long center bolts on both


sides of the drum. Insert the pry bar on top of the
drum to lift the wall fractionally while tightening the
bolts, as this will prevent the gasket from tearing.
2. Use a spray adhesive to fasten a strip of insulation to
both of the inside edges of the wall where the smaller
portion of the rear wall will be attached (Figure 3-
14).
3. Move the corner section of the rear wall into position
taking care not to let the insulation get caught in the
joint. Install the end plates connecting the pieces of
wall together and remove the wedge. After ensuring
that the wall is flush with the other section of the
wall, lightly tighten the endplate.
Figure 3-13. Align wall with base angle
Figure 3- 14

Figure 3-14. Silicone and gasket, rear wall

3-10 750-192
Model FLE Assembly Casing Assembly

4. With bar clamps, clamp the walls together at the cor-


ners of the wall and clamp the entire wall to the base
of the boiler (Figure 3-15).
5. Make sure that the walls are flush with each other
and secure all of the bolts.
6. Remove the clamps.
7. Check that the sides of the wall line up with the base
angles. If not, loosen the bolts and/or nuts on the
bolting plates and move the wall. If the wall will not
line up exactly, then center the wall in relation to the
base angles. Tighten the nuts and bolts on the bolt-
ing plates to secure the walls to the base.
8. Attempt to slide a box cutter into all of the seams
where insulation is visible. If the knife is able to
enter, then gasses can escape. Tighten the bolts and
repeat the last three steps.
9. Trim all of the visible insulation from the joints.
10. If necessary, use the wedge described earlier, to
Figure 3-15. Use bar clamps and wedges to align make the wall stand upright.
wall 11. Install a pyro-log insulation block (872-911) in the
pass opening near the rear and in the gap left by the
tubes at the bottom (Figure 3-16). The insulation
block should be compressed together slightly and
should be installed flush with the outside of the
tubes. They should be turned vertically to fill in the
turn around area. Trim to fit as necessary.

Figure 3-16. Insulation in the gaps

Figure 3-17. Use bar clamps and wedges to align


wall

750-192 3-11
Casing Assembly Model FLE Assembly

4. Drill Rear Sight Port


Table 3-1: Sight port height from lower drum
The sight port drilling process is required to remove
Flextube Size Dimension the insulation from inside the rear wall to allow the
250 13”
350 18” burner flame to be viewed during operation.
500/800/1100 20”
1. Set your tape measure to the length shown in the
table and place it at the front of the lower boiler drum
(where the front casing wall will be). This dimension
is the same as the distance from the top surface of
the lower drum to the centerline of the sight port
(Figure 3-18, 3-19).
2. Drill a 1” hole through the insulation in the center of
the sight port, parallel to the drum (Figure 3-20).
The tape measure is in approximately the same loca-
tion that the flame will be.
3. Obtain a 1” OD tube x 16” long (3/4” conduit) to use
as a guide pipe. Use the guide pipe as an applicator
and add rigidizer solution (part# 872-00458, not
included in FLE boiler assembly) to the outside of the
pipe and apply it to the inside diameter of the hole in
the insulation. Dip the pipe and coat the insulation
Figure 3-18. Set tape measure to sight port height four to six times from the rear of the boiler and repeat
(height varies with flextube size) from inside. Ensure that the insulation is thoroughly
coated with the rigidizer solution (Figure 3-21).

Figure 3-19. Overall tape measure length should


match sight port height

Figure 3-21. Coating sight hole with rigidizer

Figure 3-20. Drill out insulation (drill level, pointing


toward tape measure)

3-12 750-192
Model FLE Assembly Casing Assembly

4. Insert the pipe from outside the boiler and direct it to


the top of the tape measure (Figure 3-22).
5. Clean up any loose insulation from outside and inside
the boiler.
6. Inspect the rear wall from inside the boiler. Push
together any open seams in the Pyrobloc insulation
and tap down the area. Pack the insulation inside the
boiler around the guide pipe ensuring that the open-
ing in the guide pipe is still pointing toward the top of
the tape measure. Pack the insulation so that there
Figure 3-22. Direct guide pipe to end of tape are no gaps and if necessary, fill any cavities using
measure (flame location when assembled and loose insulation removed from the drilling process.
operating) After the insulation has been packed around the
guide pipe, remove the guide pipe (Figure 3-23).

NOTE: The hole MUST be positioned to


view the tape measure. Repeat steps 4
and 6 until it is visible.
7. Coat the end of the ceramic fibre tube in fibrefax.
Insert the tube into the sight port so that it is touch-
ing the insulation.
8. To complete the rear sight port installation, install the
sight glass cap that comes with the casing assembly
kit.

Figure 3-23. Pack insulation around sight port and


apply rigidizer to inside of sight port opening.

750-192 3-13
Casing Assembly Model FLE Assembly

5. Finishing the Wetpack Installation


Around the Lower Drum
• Unfold the wetpack to cover the lower drum and
tubes. Cover the entire base drum, overlapping
adjoining wetpack rolls. Continue to mold the wet-
pack around the lower drum and tube sections to
prevent the plates from coming apart while packing
the insulation (Figure 3-24).

• The wetpack should be positioned to be level with, or


Figure 3-24. Finishing the Wetpack Insulation just outside the base refractory at the front.
Installation

6. Finish Installing Backing Plates


• As in step 3, install the front upper and lower back-
ing plates.

7. Install Front Wall Section


To install the front wall section, repeat the same
steps used to install the rear wall. In a hot water
unit, the front wall will be one piece and the instal-
lation will be much easier, but the front wall of a
steam boiler will have two pieces just like the rear.

8. Install Roof Panel


• Tidy the top of the walls to get them ready for the
roof (pack the insulation, wipe off the wall, etc) (Fig-
ure 3-25).
• Fill any joints in the top of the front and rear walls
with silicone caulking (Figure 3-26).
Figure 3-25. Packing the Top of the Walls • Using spray adhesive, place a strip of 1/4” paper
gasket along the width of the front and rear walls
(Figure 3-27). Using the same process, place a small
square of the material on the 4 inside corners of the
walls, allowing a little metal to show through (Figure
3-28).

Figure 3-26. Filling the Joint with Silicone Caulking

3-14 750-192
Model FLE Assembly Casing Assembly

• In the roof, cut the hole for the front lift lug. This hole
should be cut on about a 45º angle.
• Position the roof to attach the front first. Attach two
washers and one nut to every bolt, level the front,
ensure the walls are flush with the edges of the roof
and tighten the bolts. Repeat this step at the back
(Figure 3-29, 30).

Figure 3-27. Insulation Strip on the Top of the Front


and Rear Walls Figure 3-29. Attaching roof panel (Note: the side
walls should have been secured to the boiler. This
photo does not show the wall.)

Figure 3-28. Insulation on Inside Corners of Front


and Rear Walls
Figure 3-30. Attaching the Roof to the Front Wall

750-192 3-15
Casing Assembly Model FLE Assembly

9. Install Burner Door


• Trim the insulation on the inside of the boiler at
a 45º angle (Figure 3-32).
• Pack any gaps in the insulation.
• Using spray adhesive, install the rope gasket on
the front wall inside the bolt pattern. This time,
the gasket should wrap around the opening
twice.
• Lift the burner door into position and install the
two 3/4" x 4-1/2” cap screws as hinge pins
• Check the swing and fit of the burner door Figure 3-32. Cutting Insulation from the Burner
against the insulation. The insulation should be Door
tight around the burner door.
• The door should be closed gently to keep the
insulation on the front wall. If the door will not
close, pull it open and tap down the insulation
in the area that is preventing the door from clos-
ing.
• Install washers and brass nuts to evenly pull the
burner door into the opening. Start at the side
farthest from the hinges, moving towards them
as you tighten.
• Look inside the opening. If any insulation is visi-
ble, it must be packed.
• Place your hand inside the opening and feel
around the opening. With the heel of your hand,
pack any gaps between the door and the insula- Figure 3-33. Tighten nuts on burner door to hold the
tion. two front wall halves together

Figure 3-31. Cut Pyrobloc from Burner door.

3-16 750-192
Model FLE Assembly Casing Assembly

10. Install Lift Lug Cover


• Using the insulation trimmed from step 8 (part 4), fill
the gap between the lift lug and the insulation.
• Pack any gaps in the insulation (Figure 3-34).
• Place a bead of silicone around the lug and on the
inside edge of the roof (Figure 3-35).
• Place the cover over the lug and silicone. If wedges
are being used, the cover should be tight to the side
opposite the lugs (ie. If the wedges are on the front of
the boiler, the cover should be tight to the rear of the
lift lug). Attach the cover so that the side tight
against the lug is screwed first (Figure 3-36).
Figure 3-35. Silicone around the Lifting Lug
• Use a putty knife and clean the surface of the cover
(Figure 3-37).

Figure 3-36. Screwing the cover tight to the Side


Opposite to the Wedges

Figure 3-34. Filling the Gaps with Insulation

Figure 3-37. Cleaning Excess Silicone from the Lid

750-192 3-17
Casing Assembly Model FLE Assembly

11. Install Drum Packing and Seal


Plates
• Pack LDS moldable insulation (872-680)
around the upper and lower, front and rear
drums to fill the void. Push it in toward the
backing plate, compressing the insulation
tightly. The insulation should be packed to
Figure 3-38. Secure Cover Plates within 1" of the outer wall.

NOTE: Use the excess pyrobloc from the


cutout of the burner door to pack around the
drums.

NOTE: Do the following three steps after


section 16 has been finished.

• Apply a layer of silicone caulk (872-420) to all sur-


Figure 3-39. Pack Insulation in faces in contact with the metal.
drum wall opening
• Install the drum seal cover plates and secure them
with the self drilling screws (842-1402).
• Insulate the steam vent with blanket insulation. Seal
it with silicone caulk and secure the cover plate to
form a strong seal.

Figure 3-40. Caulk and silicone drum wall opening

Figure 3-41. Insulate, caulk and silicone steam vent

3-18 750-192
Model FLE Assembly Casing Assembly

12. Install Insulation Under Tubes


• Install pyro-log insulation blocks (872-911) in the
pass openings near the rear and in the gap left by the
tubes at the bottom (Figure 3-42). The insulation
blocks should be compressed together slightly and
should be installed flush with the outside of the
tubes. They should be turned vertically to fill in the
turn around area. Trim to fit as necessary.
• Install 1-1/2" blanket insulation (872-279) below the
boiler tubes, on top of the refractory running the full
length of the boiler (Figure 3-43 and 44). Boilers
sizes 150 through 350 do not get this strip of insula-
tion.
• Install a 12" x 12" piece (14” by 14” for 800-1000)
of 1-1/2" blanket insulation at the rear of the boiler in
the refractory on both sides. Use a spray adhesive to
hold the insulation in place (Figure 3-43).
Figure 3-42. Insulation in the Gaps • Install 1-1/2" blanket insulation in front of the first 1-
1/2” strip of insulation and on the refractory from the
front wall to the 12" x 12" piece of insulation at the
rear of boiler (Figure 3-44).

! WARNING
DANGER
Do not leave gaps when installing insulation.
Always ensure a secure fit between the insula-
tion and any attaching or abutting surfaces, as
well as between adjacent pieces of insulation.
Failure to observe this precaution may result in
Figure 3-43. 1-1/2" blanket insulation on refractory equipment failure or unsafe operation.
tile with square piece
13. Install Pass Insulation
• Spray adhesive (94-475) on the tubes above and
below the pass opening. Install 1-1/2" blanket insula-
tion onto the entire side of the tubes and pyro-log,
pressing it onto the adhesive. Trim any excess blan-
ket at the end.
Note: As with all insulation, the pyro-log should
be tight to the next piece and to the refractory
bricks with no gaps.
Note: the blue rigidizer faces inside.

Figure 3-44. Top view of the three different pieces of


blanket insulation

Figure 3-45. Insulation along Pass Opening

750-192 3-19
Casing Assembly Model FLE Assembly

14. Prepare for Inner Casing Installa-


tion
• Using a box cutter, trim any gasket that shows
through the sides at the top of the front and back
sections. Clean the area. Wipe off the sealing surface
(the inside edge of the rear, and front walls, the roof
and the base) and remove any lumps (Figure 3-46).
• Apply silicone caulk (872-240) to the seam between
the roof and the end wall (Figure 3-47).
• Use extra pieced of insulation to fill the gaps near the
interior seams at the bottom of the front and rear
walls. After ensuring that the void is filled, clean the
area (bottom left corner of Figure 3-43).
Figure 3-46. Trimming the excess gasket and wiping
the sealing surface • Apply the expanded PTFE gasket (32-2560) to the
boiler. The gasket should be positioned approxi-
mately 1/8" (Figure 3-48) from the inside edge of the
frame. Start at the front of the roof (Figure 3-49) and
run a continuous gasket around the entire side of the
boiler. Overlap the ends of the gasket by 3" or 4" by
running the gasket side by side, not crossing or on
top of each other (Figure 3-50). The gasket has an
adhesive strip attached; however, a spray adhesive
may be used to hold the gasket in place.

Figure 3-47. Silicone around the gasket at the seam


between the roof and the wall

Figure 3-49. Gasket starts at the roof

Figure 3-48. Gasket positioned 1/8" from the inside

Figure 3-50. Gasket Ends at the roof in a tight seal

3-20 750-192
Model FLE Assembly Casing Assembly

15. Prepare the Inner Casing Panels


for Installation

• Pack the insulation on the panels. It should be


pushed from the top and bottom of the panel while
tapping the insulation into the panel. After this is fin-
ished, check that there are no holes between the
insulation and the panel (Figure 3-51).
• Place a gasket on the side of the panel. It should go
Figure 3-51. Insulation on the side Panel after the full height of the panel from the top to the bot-
packing tom. Ensure that the gasket protrudes out the inside
wall slightly (approximately 1/16") at the top and the
bottom of the panel. It should be just above the holes
in the middle of the panel (Figures 3-52-55).

Figure 3-52. Top Gasket Placement on the Side


Panel

Figure 3-54. Gasket on the inner panels

Figure 3-53. Gasket Placement on the Side of the


Side Panel

Figure 3-55. Gasket on the inner panels

750-192 3-21
Casing Assembly Model FLE Assembly

14. Install Inner Casing


NOTE: DO NOT touch the insulation when you are
moving the panels. This can cause the insulation
to move and undo the work from step 13. Try not
to let the insulation touch the boiler until it is in its
resting position (Figure 3-56).

• The inner casing panels are to be oriented so that the


two lift lugs are closer to the top
• Panels should be installed starting in the middle. Figure 3-56. Lifting the panels into position, taking
Place the 1st (middle) panel on the base. Install a care not to touch the insulation
washer and place the nuts (several turns) on the 2nd
and 4th stud. Repeat this at the top of the panel.
• Using the pipe dope, seal the seam of the gaskets at
the top and bottom of the center panel (Figure 3-57).
• Install the next two panels by positioning them so
that the bottom of the panel is at the same level as
the middle panel. Angling it into position first rather
than setting the panel on the studs and sliding it into
position may be easier. Install the two nuts on the top
and bottom, and place the remaining nuts. Repeat as
necessary until panels are installed. Figure 3-57. Sealing the seam between the gaskets
• Place bolts in the two vertical seams between the
panels. Starting at the top of the rear panel and
working down, tighten the bolts. Repeat this on the
front panel. After finishing this, return to the rear
panel and tighten to the bottom; repeat this on the
front panel (Figure 3-58).
• Install the nuts and washers around the outside of
the wall and evenly pull the panels to the boiler. Start
in the middle of the bottom bolts, tighten them work-
ing out and stop at the last 4 bolts. Repeat this at the
top, front and rear. When you are tightening the
remaining bolts, work out to the corners, starting at
the inside 8 bolts, then with the next 8 and so on,
until you tighten the corners. The bolts should be
tightened to a torque of 90 in-lb. Figure 3-58. Tightening the bolts connecting the
panels
Repeat these steps on the other side of the boiler.
! WARNING
DANGER
The panel bolts should be tightened to a torque
of 90 in-lb (7-1/2 ft-lb). Do not over-tighten.

3-22 750-192
Model FLE Assembly Casing Assembly

17. Install Outer Casing


• Stick the approximately 2” square pieced of insula-
tion on the inner casing. Each panel will receive two
pieces, one at the top and another in the middle near
the bottom. See the drawings for placement loca-
tions.
• Position the roof casing on the top frame edge so that
the 4-1/4" side is on top. Line up the edge of the
edge of the casing with the inside of the roof and
clamp it into position. Attach it and remove the
clamps (Figure 3-59).
• Install the outer casing panels by sliding the top
under the roof casing and then swinging the bottom
into the boiler and sliding it down over the bottom
angle. Install all panels in this manner. Panels should
be positioned so that they are centered with equal
lengths of uncovered area at the ends (Figure 3-60).
• Push the panels together and fix screws to the bot-
tom outside corners of the panels to ensure that they
do not move laterally.
• Secure the roof casing with the self tapping screws,
at each end and with one in the center of the top
frame outer casing.
• Position the corner casings and secure them to the Figure 3-60. Outer Casing Panels
end walls and roof casing (Figure 3-61).

Figure 3-59. Top Frame of Outer Casing

Figure 3-61. Attaching corner casings

750-192 3-23
Casing Assembly Model FLE Assembly

3-24 750-192
CHAPTER 4 The gas train components are shipped assembled
but mounting the gas train to the base and
Burner Assembly, Gas Train, plumbing to the burner is required in the field
assembly.
and Boiler Controls Installation
Check that all connections are tight following the
1. Burner Mounting . . . . . . . . . . . . . . . . . . . 4-1 completion of the gas train plumbing (components
2. Burner Connections . . . . . . . . . . . . . . . . . 4-1 may have loosened or moved during shipping).
3. Gas Train Mounting . . . . . . . . . . . . . . . . . 4-1 Pressurize the gas train with 1 psig of air pressure
4. Electrical Connections and Layout . . . . . . . 4-3 and using a soapy water solution, either spray or
brush the solution on all connections. If bubbles are
The burner used to fire the Model FLE series boiler evident, the suspected connection must be
is mounted to a burner door which allows access to disassembled and checked for damage. After
the boiler combustion chamber for inspection and completing the inspection, seal, reassemble and re-
maintenance. Fuel and electrical connections to the test the connection.
burner must be made so as to allow the burner door
to be opened as intended.

1. Burner Mounting
Apply adhesive and a rope gasket to the burner
extension tube flange on the burner door. The rope
gasket should wrap around the burner extension
flange at lease 3 times. Apply the anti-seize
compound to the burner mounting studs.

Lift the burner and insert the burner extension tube


into the burner door opening. Install clamps,
washers, and nuts to the burner mounting studs.
With a bubble level atop the burner control cabinet,
level the burner. Tighten the mounting nuts evenly to
achieve a uniform compression of the burner flange
Figure 4-1. Burner Support
gasket.

Bolt on the burner support. Smaller burners do not


require this support and it will not be provided for
them.

2. Burner Connections
Electrical and fuel connections to the burner must
be made in accordance with all applicable state and
local codes, as well as any insurers requirements
that may apply.

3. Gas Train Mounting


The gas train for a ProFire burner is mounted to the
base frame on the right side of the boiler.

750-192 4-1
Figure 4-2. Fuel Train Components
750-192
4-2
4. Electrical Connections and Layout
The electrical connections and routing should follow
the illustrations in this manual. Conduit, wiring and
connections are supplied for the layout described.
Deviation from the recommended wiring layout
could result in a shortage of required material.

Use the wiring diagram supplied with the boiler in


conjunction with the illustrations in this manual for
layout and wiring purposes.

Figure 4-4. Typical Conduit Layout with a Profire


Burner on a Steam Flextube Boiler
Figure 4-3. Typical Conduit Layout with a Profire
Burner on a Hot Water Flextube Boiler

750-192 4-3
4-4

Figure 4-5. Typical conduit layout - ProFire burner on a hot water Flextube boiler
750-192
Figure 4-6. Typical conduit layout - ProFire burner on a steam Flextube boiler
750-192
4-5
4-6
Figure 4-7. Nameplate locations, hot water boiler
750-192
Figure 4-8. Nameplate locations, steam boiler
750-192
4-7
e-mail: info@cleaverbrooks.com
Web Address: http://www.cleaverbrooks.com