Model FLE -...

Model FLE

Assembly Instructions

750-35711/2013

Field Erectable Flexible Watertube BoilerSizes 1250-2500

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! DANGERWARNINGIf the information in this manual is not fol-lowed exactly, a fire or explosion may re-sult causing property damage, personalinjury or loss of life.

— Do not store or use gasoline or otherflammable vapors and liquids in the vicin-ity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.• Do not touch any electrical switch; do

not use any phone in your building.• Immediately call your gas supplier

from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

— Installation and service must be per-formed by a qualified Cleaver-Brooks, service agency or the gas supplier.

Improper installation, adjustment, service, ormaintenance can cause equipment damage,personal injury, or death. Refer to the Opera-tion and Maintenance manual provided withthe boiler. Installation and service must beperformed by a qualified Cleaver-Brooks ser-vice provider.

! DANGERWARNING

! DANGERWARNING

Be sure the fuel supply which the boilerwas designed to operate on is the sametype as specified on the boiler nameplate.

! DANGERWARNING

Should overheating occur or the gas sup-ply valve fail to shut off, do not turn off ordisconnect the electrical supply to theboiler. Instead turn off the gas supply at alocation external to the boiler.

! DANGERWARNING

Do not use this boiler if any part has beenunder water. Immediately call your Cleav-er-Brooks service representative to in-spect the boiler and to replace any part ofthe control system and any gas controlwhich has been under water.

! DANGERWARNINGTo minimize the possibility of serious per-sonal injury, fire or damage to the equip-ment, never violate the following safety rules. — Always keep the area around the boiler free of combustible materials, gasoline, and other flammable liquids and vapors— Never cover the boiler, lean anything against it, stand on it, or in any way block the flow of fresh air to the boiler.

This manual must be maintained in legi-ble condition and kept adjacent to theboiler or in a safe place for future refer-ence. Contact your local Cleaver-Brooksrepresentative if additional manuals arerequired.

Notice

Where required by the authority havingjurisdiction, the installation must conformto the Standard for Controls and SafetyDevices for Automatically Fired Boilers,ANSI/ASME CSD-1.

Notice

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The installation must conform to the re-quirements of the authority having jurisdic-tion or, in the absence of suchrequirements, to UL 795 Commercial-In-dustrial Gas Heating Equipment and/orthe National Fuel Gas Code, ANSI Z223.1

! DANGERWARNINGThe boiler and its individual shutoff valvemust be disconnected from the gas sup-ply piping system during any pressuretesting of that system at test pressures inexcess of 1/2 psi (3.5 kPa).

! DANGERWARNING

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Notes

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

Manual Part No. 750-357

11/2013 Printed in U.S.A.

Cleaver-Brooks 2013

CLEAVER-BROOKSModel FLE Field Erectable

Flexible Watertube Boiler 1250-2500Assembly Instructions

vi

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 thecomponents are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severepersonal injury or death.

It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel whoare 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 electricaland 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 andhazards inherent in handling and firing of fuel.

Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merelyfree 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 instructionscan replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of theresponsibility 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 varyconsiderably 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 intheir daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead touneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness anddeficiencies 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 theneed 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 stoppageswhich could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspectedfrequently 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 properboiler water treating practices.

The operation of this equipment by the owner and his or her operating personnel must comply with all requirements orregulations 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.

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 SEVEREPERSONAL INJURY OR DEATH.

! DANGERWARNING

CONTENTS

CHAPTER 1General Description

1. The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12. Transportation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . 1-23. Order of Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44. Pressure Vessel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45. Casing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56. Burner and Fuel Piping Installation . . . . . . . . . . . . . . . . . . . . . 1-67. Trim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

CHAPTER 2Pressure Vessel Assembly

1. Preparation for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12. Position the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33. Level the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34. Positioning the Lower Drum on the Base . . . . . . . . . . . . . . . . . 2-35. Upper Drum Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46. Attaching Lower Drum to Base. . . . . . . . . . . . . . . . . . . . 2-46. Check All Drum Holes and Studs . . . . . . . . . . . . . . . . . . . . . . 2-47. Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78. Ferrule Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-219. Pass Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2210. Installation of Pressure Vessel to Base . . . . . . . . . . . . . . . . 2-2311. Pressurized Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

CHAPTER 3Casing Assembly

1. Install Wetpack around Vent Tube and Lower Drum . . . . . . . . . 3-82. Install Backing Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83. Install Rear Wall Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96. Finish Installing Backing Plates . . . . . . . . . . . . . . . . . . . . . . 3-117. Install Front Wall Section . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118. Install Roof Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119. Install Burner Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . 3-1210a. Install Seal Ring [steam units] . . . . . . . . . . . . . . . . . . . . . 3-1210b. Install Lift Lug Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1211. Seal weld end walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1312. Install Drum Packing and Seal Plates . . . . . . . . . . . . . . . . . 3-1413. Install 5th Pass Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1413. Install Insulation Under Tubes . . . . . . . . . . . . . . . . . . . . . . 3-1514. Install Pass Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1515. Prepare for Inner Casing Installation . . . . . . . . . . . . . . . . . . 3-1616. Prepare the Inner Casing Panels for . . . . . . . . . . . . . . . . . . 3-1717. Install Inner Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1818. Casing Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1919. Install Outer Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

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CHAPTER 4Burner Installation

1. Burner Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12. Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13. Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34. Electrical Connections and Layout . . . . . . . . . . . . . . . . . . . . . .4-45. FGR System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

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Model FLE Assembly General Description

CHAPTER 1General Description

1. The Boiler . . . . . . . . . . . . . . . . . . . . . . . . 1-12. Transportation and Handling . . . . . . . . . . . 1-23. Order of Assembly . . . . . . . . . . . . . . . . . . 1-44. Pressure Vessel Assembly . . . . . . . . . . . . . 1-45. Casing Assembly . . . . . . . . . . . . . . . . . . . 1-56. Burner and Fuel Piping Installation . . . . . . . 1-67. Trim Installation . . . . . . . . . . . . . . . . . . . . 1-6

1. The Boiler

The Cleaver-Brooks Model FLE Boiler is a field-erectable, five-pass, steel boiler. Its flexible, replaceable, water-tubes are formed and arranged to direct the flow of combustion gases through the boiler as illustrated in Figure 1-1.

Figure 1-1. FLE Five-Pass Construction

The hot water unit has a single rear flanged external rear downcomer while the steam unit has flanged downcomers on both the front and rear. All units have top and bottom drums. In the hot water unit, the top and bottom drums are the same diameter, but in the steam units, the top drum of a steam unit is larger than the bottom. The pressure vessel is designed and fabricated in accordance with the ASME Boiler and Pressure Vessel code.

The heated area of the pressure vessel is contained within an insulated casing that is composed of removable, formed steel panels. The fuel/air mixture from the burner combusts in the furnace area, then exit the furnace (pass one) to flow through four additional front-to-back passes formed by the arrangement of the watertubes within the boiler casing.

750-357 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. FLE Boiler Tubes Being Readied to Ship

Table 1-1: Boiler Components, Approx. Weights and Sizes (Hot Water)PARTS HOT WATER

DESCRIPTION INFO 1250 1450 1650 1850 2100 2500

Base Assembly PART NO. 003-02522-000 003-02527-000 003-02635-000 003-02637-000 003-02526-000 003-02543-000

(Insulated) APPROX. SIZE (in) 53-1/2x188-3/4 53-1/2x203-3/4 60x217-3/4 60x231-3/4 75x245-3/4 75x275-7/8

WEIGHT (lb) 2110 2290 2750 2950 4215 4745

Front Wall PART NO. 105-12203-000 105-12203-000 105-12364-000 105-12364-000 105-12222-000 105-12222-000

Large Piece(Insulated)

APPROX. SIZE (in) 45-1/2x83-3/4 45-1/2x83-3/4 53x95-1/4 53x95-1/4 68x118 68x118

WEIGHT (lb) 277 277 360 360 574 574

Front Wall PART NO. 105-12442-000 105-12442-000 105-12444-000 105-12444-000 105-12255-000 105-12255-000

Corner Piece(Insulated)

APPROX. SIZE (in) 22-23/32x27 22-23/32x27 26-15/32x31-3/16 26-15/32x31-3/16 33-31/32x34-15/16

33-31/32x34-15/16

WEIGHT (lb) 72 72 92 92 125 125

Rear Wall PART NO. 105-12204-000 105-12204-000 105-12365-000 105-12365-000 105-12223-000 105-12223-000


APPROX. SIZE (in) 45-1/2x83-3/4 45-1/2x83-3/4 53x95-1/4 53x95-1/4 68x118 68x118

WEIGHT (lb) 386 386 472 472 678 678

Rear Wall PART NO. 105-12205-000 105-12205-000 105-12366-000 105-12366-000 105-12224-000 105-12224-000


APPROX. SIZE (in) 22-23/32x27 22-23/32x27 26-15/32x31-3/16 26-15/32x31-3/16 33-31/32x34-15/16

33-31/32x34-15/16

WEIGHT (lb) 61 61 79 79 109 109

Roof Assembly PART NO. 105-12211-000 105-12231-000 105-12370-000 105-12377-000 105-12232-000 105-12259-000

(Insulated) APPROX. SIZE (in) 45-1/2x156-1/4 45-1/2x171-1/4 53x185-1/4 53x199-1/4 68x213-1/4 68x243-3/8

WEIGHT (lb) 498 545 670 709 1008 1149

Upper Drum PART NO. 270-03720-000 270-03722-000 270-03856-000 270-03858-000 270-03716-000 270-03728-000

Assembly APPROX. SIZE (in) 10x191-1/4 10x206-1/4 10x226-3/8 10x240-3/8 12x257-5/8 12x287-5/8

WEIGHT (lb) 750 790 900 940 1210 1350

Lower Drum PART NO. 270-03721-000 270-03723-000 270-03857-000 270-03859-000 270-03714-000 270-03727-000

Assembly APPROX. SIZE (in) 10x191-1/4 10x206-1/4 10x223-5/8 10x237-5/8 12x255-5/8 12x284-5/8

WEIGHT (lb) 720 770 870 910 1180 1320

Inner Casing PART NO. * * * * * *

Panels(Insulated)

APPROX. SIZE (in) 34-1/2x86-1/4 34-1/2x86-1/4 34-1/2x97-3/4 34-1/2x97-3/4 37-3/4x120-1/2 37-3/4x120-1/2

WEIGHT (lb) 100 100 112 112 185 185

Outer Casing PART NO. * * * * * *

Panels(Insulated)

APPROX. SIZE (in) 34-1/2x86-1/2 37-1/2x86-1/2 34-1/2x98 34-1/2x98 37-3/4x120-3/4 37-3/4x120-3/4

WEIGHT (lb) 50 54 57 57 75 75

Burner Dry Oven PART NO. 279-00628-000 279-00628-000 279-00658-000 279-00658-000 279-00635-000 279-00635-000

APPROX. SIZE (in) 27-1/2x27-1/2 27-1/2x27-1/2 28-1/2x28-1/2 28-1/2x28-1/2 31-1/2x31-1/2 31-1/2x31-1/2

WEIGHT (lb) 210 210 235 235 300 300

Tubes PART NO. 093-10204-000 093-10216-000 093-10733-000 093-10765-000 093-10167-000 093-10274-000

QUANTITY 190 210 172 186 200 230

WEIGHT (lb) 3725 4130 5830 6325 8900 10250

TOTAL WEIGHT 12800 13800 16900 17700 24300 27200

* Various part numbers are used for each size

1-2 750-357

Table 1-1b Boiler Components, Approx. Weights and Sizes (Steam)PARTS HIGH PRESSURE STEAM LOW PRESSURE STEAM

DESCRIPTION INFO 1250 1450 1650 1850 2100 2500 1250 1450 1650 1850 2100 2500

Base Assembly PART NO. 003-02522-000 003-02527-000 003-02635-000 003-02637-000 003-02526-000 003-02543-000 003-02522-000 003-02527-000 003-02635-000 003-02637-000 003-02526-000 003-02543-000

(Insulated) APPROX. SIZE (in) 53-1/2x188-3/4 53-1/2x203-3/4 60x217-3/4 60x231-3/4 75x245-3/4 75x275-7/8 53-1/2x188-3/4 53-1/2x203-3/4 60x217-3/4 60x231-3/4 75x245-3/4 75x275-7/8

WEIGHT (lb) 2110 2290 2750 2950 4215 4745 2110 2290 2750 2950 4215 4745

Front Wall PART NO. 105-11930-000 105-11930-000 105-12130-000 105-12130-000 105-12085-000 105-12085-000 105-11930-000 105-11930-000 105-12130-000 105-12130-000 105-12085-000 105-12085-000


APPROX. SIZE (in) 45-1/2x101-1/2 45-1/2x101-1/2 53x109-1/2 53x109-1/2 68x135-1/2 68x135-1/2 45-1/2x101-1/2 45-1/2x101-1/2 53x109-1/2 53x109-1/2 68x135-1/2 68x135-1/2

WEIGHT (lb) 300 300 375 375 605 605 300 300 375 375 605 605

Front Wall PART NO. 105-11932-000 105-11932-000 105-12132-000 105-12132-000 105-12104-000 105-12104-000 105-11932-000 105-11932-000 105-12132-000 105-12132-000 105-12104-000 105-12104-000


APPROX. SIZE (in) 22-23/32x44-3/4 22-23/32x44-3/4 26-15/32x45-7/16 26-15/32x45-7/16 33-31/32x52-7/16 33-31/32x52-7/16 22-23/32x44-3/4 22-23/32x44-3/4 26-15/32x45-7/16 26-15/32x45-7/16 33-31/32x52-7/16 33-31/32x52-7/16

WEIGHT (lb) 90 90 110 110 155 155 90 90 110 110 155 155

Rear Wall PART NO. 105-11929-000 105-11929-000 105-12129-000 105-12129-000 105-12086-000 105-12086-000 105-11929-000 105-11929-000 105-12129-000 105-12129-000 105-12086-000 105-12086-000


APPROX. SIZE (in) 45-1/2x101-1/2 45-1/2x101-1/2 53x109-1/2 53x109-1/2 68x135-1/2 68x135-1/2 45-1/2x101-1/2 45-1/2x101-1/2 53x109-1/2 53x109-1/2 68x135-1/2 68x135-1/2

WEIGHT (lb) 405 405 490 490 705 705 405 405 490 490 705 705

Rear Wall PART NO. 105-11954-000 105-11954-000 105-12139-000 105-12139-000 105-12087-000 105-12087-000 105-11954-000 105-11954-000 105-12139-000 105-12139-000 105-12087-000 105-12087-000



WEIGHT (lb) 80 80 95 95 135 135 80 80 95 95 135 135

Roof Assembly PART NO. 105-12451-000 105-12451-000 105-12469-000 105-12472-000 105-12480-000 105-12486-000 105-12451-000 105-12451-000 105-12469-000 105-12472-000 105-12480-000 105-12486-000

(Insulated) APPROX. SIZE (in) 45-1/2x156-1/4 45-1/2x171-1/4 53x185-1/4 53x199-1/4 68x213-1/4 68x243-3/8 45-1/2x156-1/4 45-1/2x171-1/4 53x185-1/4 53x199-1/4 68x213-1/4 68x243-3/8

WEIGHT (lb) 485 530 645 695 995 1135 485 530 645 695 995 1135

Upper Drum PART NO. 270-03650-000 270-03707-000 270-03700-000 270-03724-000 270-03694-000 270-03710-000 270-03717-000 270-03703-000 270-03853-000 270-03726-000 270-03713-000 270-03715-000

Assembly APPROX. SIZE (in) 28x198 28x213 28x231-1/2 28x245-1/2 32x259-1/2 32x289-1/2 28x200-1/2 28x215-1/2 28x234 28x248 32x264-1/2 32x294-1/2

WEIGHT (lb) 2970 3140 3460 3640 4520 4890 2780 2940 3270 3420 4150 4510

Lower Drum PART NO. 270-03651-000 270-03708-000 270-03701-000 270-03725-000 270-03693-000 270-03709-000 270-03718-000 270-03704-000 270-03701-000 270-03725-000 270-03693-000 270-03709-000

Assembly APPROX. SIZE (in) 10x197 10x212 10x230-1/2 10x244-1/2 12x258-1/2 12x288-1/2 10x197 10x212 10x230-1/2 10x244-1/2 12x258-1/2 12x288-1/2

WEIGHT (lb) 890 940 1120 1170 1450 1570 890 940 1120 1170 1450 1570

Inner Casing PART NO. * * * * * * * * * * * *

Panels(Insulated)

APPROX. SIZE (in) 34-1/2x104 34-1/2x104 34-1/2x112 34-1/2x112 37-3/4x138 37-3/4x138 34-1/2x104 34-1/2x104 34-1/2x112 34-1/2x112 37-3/4x138 37-3/4x138

WEIGHT (lb) 125 125 135 135 212 212 125 125 135 135 212 212

Outer Casing PART NO. * * * * * * * * * * * *

Panels(Insulated)


WEIGHT (lb) 60 65 65 65 86 86 60 65 65 65 86 86

Burner Dry Oven PART NO. 279-00628-000 279-00628-000 279-00658-000 279-00658-000 279-00635-000 279-00635-000 279-00628-000 279-00628-000 279-00658-000 279-00658-000 279-00635-000 279-00635-000


WEIGHT (lb) 210 210 235 235 300 300 210 210 235 235 300 300

Tubes PART NO. 093-09589-000 093-10137-000 093-10118-000 093-10223-000 093-10038-000 093-10143-000 093-09589-000 093-10137-000 093-10118-000 093-10223-000 093-10038-000 093-10143-000

QUANTITY 190 210 172 186 200 230 190 210 172 186 200 230

WEIGHT (lb) 3730 4460 5750 6235 8800 10165 3730 4460 5750 6235 8800 10165

TOTAL WEIGHT 16000 17300 21200 22200 30500 34100 16000 17300 21200 22200 30500 34100

* Various part numbers are used for each size


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.

The steps involved in boiler assembly are:

1. Pressure vessel assembly and water side leak test (Chapter 2)

2. Casing assembly and fireside leak test (Chapter 3)

3. Burner assembly and gas train installation (Chapter 4)

The boiler components are listed in Table 1-1. Special assembly equipment likely to be required for each part of the assembly process is listed below.

There are three different types of insulation used in the construction of the Cleaver-Brooks Flextube Model boilers:

• Ceramic fiber- white, flexible, dry insulation, supplied in bulk roll or block

• Wet-pack- white, flexible, insulation saturated with curing agent, supplied as rolls in sealed bags

• Fibrefrax- 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 620)• Anti-seize lubricant• Tube retainers and fasteners• Spray adhesive

Figure 1-3. ProFire burner mounted on a Model FLE

The following tools will be required to assemble the pressure vessel:

• Small and large level• Vice-grip clamp or strap wrench• Chain fall and support strapping• Lifting support• Tube driving tools and 16 or 20 lb sledge hammer• 5/8” die• Dulled chisel• Slings and chains• Lifting and support devices (come-along, ratchet

hoist, etc.)• Caulking gun• Safety glasses, hearing protection and gloves• Suitable lifting equipment will be required to handle

the placement of the drums and the mounting of the completed vessel to the base

Figure 1-4. Model FLE (Steam)

1-4 750-357

Model FLE Assembly General Description

Note: • Building the vessel in a vertical position will require

support from the top. • Drum placement is best accomplished when the base

is used as an initial building jig. • A steam boiler will become structurally rigid with the

coupling of the front and rear downcomers. • Check the levelness of the base to the lower drum

and subsequently the downcomers and upper drum frequently.

Full sledge hammer swings, organized tube delivery and efficient clamping will expedite vessel assembly. Contact your C-B representative for estimated time required to assemble.

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

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)

The tools required to install the casing include:

• Hand tools, 1/2” drive ratchet and sockets• Wedges or dulled chisel• Pry bars and tapered alignment pins• Cartridge caulk applicator• Slings and chains• Lifting devices (come-along, ratchet hoist, etc.)• Razor knife, putty knife• Four, 5 foot bar clamps

Figure 1-5. Model FLE (Hot Water)

750-357 1-5


Figure 1-6. Trim Components (Steam)

Figure 1-7. Typical Gas Train

Figure 1-8. Trim Components (Hot Water)

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.

1 23

4

1. Operating limit control2. High limit control3. Pressure transmitter4 Pressure gauge

1-6 750-357

Model FLE Assembly Pressure Vessel Assembly

CHAPTER 2Pressure Vessel Assembly

1. Preparation for Assembly . . . . . . . . . . . . . 2-12. Position the Base . . . . . . . . . . . . . . . . . . . 2-33. Level the Base . . . . . . . . . . . . . . . . . . . . . 2-34. Positioning the Lower Drum on the Base . . . 2-35. Upper Drum Placement . . . . . . . . . . . . . . 2-46. Attaching Lower Drum to Base . . . . . . . . . . 2-47. Check All Drum Holes and Studs . . . . . . . . 2-48. Tube Installation . . . . . . . . . . . . . . . . . . . 2-79. Ferrule Retainers . . . . . . . . . . . . . . . . . . 2-2110. Pass Seals . . . . . . . . . . . . . . . . . . . . . . 2-2211. Installation of Pressure Vessel to Base . . 2-2312. Pressurized Leak Test . . . . . . . . . . . . . . 2-23

1. Preparation for Assembly

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.

Before beginning assembly of the pressure vessel the required component parts should be brought to the work area and organized. The time required to assemble the pressure vessel will be affected by the ease with which the correct part can be located, and by the proximity of the parts storage to the work area.

All joined fittings, whether they are driven ferrules or 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

surfaces, bent or dented tubes, etc) should be replaced.

CAUTION

Drum tube holes may have sharp edges from the machining process. In order to prevent cuts or serious personal injury, gloves should be worn when cleaning.

The ferrule joint must be clean and free of oil and debris in order to protect the lubricating and sealing properties of the ferrule joint and sealant.

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 are adequate to support the weight of the components being lifted. Failure to follow this warning may result in serious personal injury or death.

750-357 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) Centerline to Centerline

Drum Length End to End

Steam Hot Water Steam Hot Water150 60 56-1/2 98 98-3/8200 60 56-1/2 98 98-3/8250 60 56-1/2 98 98-3/8300 64 60-1/2 104 104-3/8350 64 60-1/2 104 104-3/8400 67 63-1/2 126 126-3/8450 67 63-1/2 126 126-3/8500 67 63-1/2 126 126-3/8550 67 63-1/2 126 126-3/8600 67 63-1/2 126 126-3/8700 77 69-1/2 150 147800 77 69-1/2 150 147900 77 69-1/2 150 147

1000 77 69-1/2 182 172-1/21100 77 69-1/2 182 172-1/21200 77 69-1/2 182 172-1/2

1250 79 69-1/2 198 191-1/41450 79 69-1/2 213 206-1/41650 87 81 231-1/2 226-5/81850 87 81 245-1/2 240-3/82100 110 102 259-1/2 256-5/82500 110 102 289-1/2 286-5/8

2-2 750-357


2. Position the Base

Figure 2-2. Placing lower drum on base

Move the base into position with lifting straps, pry 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 the Base

Position the lower drum on the base but do not weld into place.

Figure 2-3. Boiler base

Figure 2-4. Bolting upper drum to downcomers

Figure 2-5. Continually check level as vessel is being assembled

Poured Refractory baseis standard.Optional 2-piecetiled base available.

750-357 2-3


5. Upper Drum Placement

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

ter Units by Size

Using appropriately sized lifting devices, place the upper drum in position above the downcomer and lower drum. Apply sealant to the downcomer gasket and position the gasket between the flanges. Using the studs provided, secure the flanges and/or front 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 hot water boilers 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 2-8. The part numbers for the drum spreaders are shown in Table 2-2. See table 2-1 for drum dimensions.

6. Attaching Lower Drum to Base

NOTE: Before welding lower drum to base, ensure upper drum is vertically aligned with the lower drum.

Ensure 1/4" clearance between end of rear mounting plate and rear of base. Weld the front and rear lower drum mounting plates to the base (see Figure 2-6).

1/4

3/8

1/4 TYP.

1/41/4

1

Figure 2-6. Weld Lower Drum to Base

7. Check All Drum Holes and Studs

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.

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.

Studs

If there are any threads causing the tube retainer studs to bind, chase them with a 5/8” die (Figure 2-8). Checking all the retainer stud threads will make

Size Part No.1250-1450 98-3241650-1850 98-3922100-2500 98-393

2-4 750-357


the assembly process go smoother. All retainer studs must be coated with “Never-Seez”.

Figure 2-7. Drum spreader in position on completed vessel

Figure 2-8. Use a 5/8" die to chase all the retainer stud threads

750-357 2-5


The pressure vessel is assembled in the factory, hydro tested and stamped. 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 2-9. Use caution when inspecting drum holes

Figure 2-10. A steam vessel (left) and a hot water vessel (right)

2-6 750-357


8. Tube Installation

Tubes are formed in eleven different patterns in order to provide a five-pass gas flow path through the boiler (Figure 2-11).

Figure 2-11. Cross section showing tubes forming the five gas passes

Note: The horizontal tubes between the first and second pass with a gap greater than 3/32” must be packed with ceramic insulation.

WARNING

Heavy-duty work gloves and hearing and eye protection must be worn by assemblers when driving boiler tubes. Failure to heed this warning may result in damage to the eyes, hearing impairment, or serious personal injury.

One member of the assembly team should become familiar with the boiler’s tube patterns and keep track of the tubes as they are installed.

Inspect the tube ferrules for flat spots or scuffs due to shipping. Repair or replace any tube that may have been damaged during shipment

Tube installation should begin at the rear of the pressure vessel, in order to take advantage of the rigidity provided by the downcomer pipe. The pressure vessel will become progressively more rigid as additional tubes are installed.

Install all of the tubes on one side of the boiler before proceeding to the other side.

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 2-12) which is seated against a raised shoulder on the tube ferrules. A 16-pound sledgehammer is recommended for driving the tubes.

Use a modified vice-grip clamp to secure the driving tool to the ferrule.

Before installing the tubes, apply a thin, uniform coat of Lock-Tite sealant (Part Number 872-00867-000) to 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 2-13).

1

23

4

5

Gas pass seal

Gas pass seal

750-357 2-7


The ferrules must be driven in to expose a maximum 7/8 inch of the tapered portion of the ferrule.

CAUTION - The tube driving tool must be securely held against the tube during the driving operation. 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 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.

To achieve a tight fit between tubes, drive the tubes to a uniform depth.

Install the remaining tubes on the right side, follow-ing the proper tube pattern sequence.

Figure 2-12. Tube Driving tools and Tube Removal Tool

Figure 2-13. Driving lower end of first tube

FLX 1250/1450: 1-1/2" Dia Tubes

Driving Tool 098-00287-000

Removal Tool "L" 943-00794-000

Removal Tool "Straight" 098-00266-000

FLX 1650/1850/2100/2500: 2" Dia Tubes

Driving Tool 943-00409-000

Removal Tool "L" 943-00413-000

Removal Tool "Straight" 943-00408-000

Tube driving and removal tools

7/8 MAX

APPLY LOCTITE SEALANTCOMPOUND RC 620 TOFERRULE OF EACH TUBEPRIOR TO INSERTION INTOBOILER

2-8 750-357

750

-357

2-9

TUBE PATTERNS, STEAM

TUBE PATTERNS, HOT WATER 1650-2500

TUBE PATTERNS, HOT WATER 1250-1450

1 2 3 4 5 6 7 8 9 10 11

1 2 3 4 5 6 7 8 9 10 11

1 2 3 4 5 6 7 8 9 10 11

2-10

750

-35

7

DESCRIPTIONPART NO.QTY

ITEM

TUBE NO. 1093-09753-00031TUBE NO. 2093-09754-00062TUBE NO. 3093-09755-00033TUBE NO. 4093-09756-00064TUBE NO. 5093-09757-000415TUBE NO. 6093-09758-000416TUBE NO. 7093-09759-000417TUBE NO. 8093-09760-000418TUBE NO. 9093-09761-00049TUBE NO. 10093-09762-000310TUBE NO. 11093-09763-000111

FRONT REARFRONTREAR

2 2 26

4 4 4 89

10

9

10

9

10

91

3

1

3

1

3

5

7

11

4

2

4

2

4

2

363646464646431

1250 1450

Tube Arrangement Steam FLX 1250-1450

750

-357

2-11

DESCRIPTIONPART NO.QTYITEM


FRONT REARFRONTREAR

2

4 10

91

3

11

2

4

10

9

10

9

10

98

6

2

4

2

4

21

3

1

3

17

52

4

2

4

2

Tube Arrangement Steam FLX 1650

2-12

750

-35

7


FRONTREAR

3

1

3

1

3

1

3

5

711

2

4

2

4

2

4

2

FRONT REAR

10

9

10

9

10

9

10

9

8

6

4

2

4

2

4

2

4

DESCRIPTIONPART NO.QTYITEMTUBE NO. 1093-10119-00031TUBE NO. 2093-10120-00072TUBE NO. 3093-10121-00043TUBE NO. 4093-10122-00074TUBE NO. 5093-10123-000395TUBE NO. 6093-10124-000396TUBE NO. 7093-10125-000397TUBE NO. 8093-10126-000398TUBE NO. 9093-10127-00049TUBE NO. 10093-10128-000410TUBE NO. 11093-10129-000111

750

-357

2-13

LEFT SIDE VIEW RIGHT SIDE VIEW


11

2

4 4

2 2

4

7

52 1

3

1

3

1

3

1

FRONTREARFRONT REAR

2

4

2

4

2

4

2

8

10

9

10

9

10

9

10

96


2-14

750

-35

7



11

2

4 4

2 2

45

2

1

3

1

3

1

3

FRONTREARFRONT REAR

2

4

2

4

2

4 10

9

10

9

10

9

10

963

74

8


750

-357

2-15

DESCRIPTIONPART NO.QTY

ITEM


1

4

1

4

1

4

7

10

8

11

8

11

8

11

86

9

6

9

6

9

2

5

3

4

1

4

1

4

1

FRONT REARFRONTREAR

646164634643463

1250 1450

Tube Arrangement Hot Water FLX 1250-1450

2-16

750

-35

7

RIGHT SIDE VIEWLEFT SIDE VIEW


FRONT FRONTREAR REAR

2

4

2

4

2

4

2 8

6 10

9

10

9

10

9

10

91

3

1

3

1

3

17

511

2

4

2

4

2

4

2

Tube Arrangement Hot Water FLX 1650

750

-357

2-17

RIGHT SIDE VIEWLEFT SIDE VIEW


REARFRONTREAR FRONT

4

2

4

2

4

2

4

6

8 10

9

10

9

10

9

10

9

3

1

3

1

3

1

3

5

711

2

4

2

4

2

4

2


2-18

750

-35

7



FRONTREARFRONT REAR

11

2 2 2 2

4 4 4

7

5

1

3

111

33

2

4

2

4

2

4

2 8

6 10

9

10

9

10

9

10

9


750

-357

2-19

LEFT SIDE VIEW

RIGHT SIDE VIEW


FRONTREAR

FRONT REAR

11

22 2 2

4 4 4 7

5 1

3

11

33

2

4

2

4

2

4

6

10

9

10

9

10

9

10

9

3 4 8



Figure 2-14. Both ends of the tube must be inserted prior to driving the tubes

Figure 2-15. Use a modified vice-grip to hold driving tool tight to the tube

Figure 2-16. Tubes driven to uniform depth

Figure 2-17. Completed Pressure Vessel

2-20 750-357


Figure 2-22. Ferrules must be driven in to expose max. 7/8 inch of the tapered portion of the ferrule

9. Ferrule Retainers

Tube ferrule retainers are provided to ensure 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 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.

CAUTION - Ferrule Retainers must be installed as the tubes are being inserted. Failure to do so can lead to the tubes popping out.

Figure 2-23. Retainer on the shoulder of a group of three ferrules

Figure 2-24. Installing retainer on ferrule shoulders

Figure 2-25. Vent tube retainer (with welded tab)

750-357 2-21


10. 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.

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 right-side tubes.

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 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.

Figure 2-26. Install pass seals before installing left side tubes

Figure 2-27. Upper pass seal installed

Figure 2-28. Lower pass seal installed

2-22 750-357


11. Installation of Pressure Vessel to Base

If the pressure vessel has been built on stands or is suspended, follow the earlier procedures for mounting and securing the pressure vessel to the base.

Figure 2-29. Figure 2- 29: Leak testing the completed pressure vessel

WARNING - The assembled Model FLE pressure vessel is heavy. Until the pressure vessel is secured to the base, it will be 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

12. 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. A pump or other pressure source capable of pressurizing the flooded 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 the drum. Relieve the hydraulic pressure, remove

the retainer plate and drive the ferrule deeper into the drum. Drive the ferrule only far enough to eliminate leakage.Table 2- 2: Recommended Pressure for Leak Test

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 pressure vessel.

CAUTION - Before resealing the ferrules, relieve pressure from the vessel. Once the ferrules are resealed, repeat the pressurized leak test.

Figure 2-30. Pressurized leak test

Boiler Design Recommended Pressure for Leak Test

15 psi Steam 15 psi150 psi Steam 150 psi

160 psi Hot Water 160 psi

750-357 2-23


2-24 750-357

Model FLE Assembly Casing Assembly

CHAPTER 3Casing Assembly

1. Install Wetpack around Vent Tube and Lower Drum . . 3-82. Install Backing Plates . . . . . . . . . . . . . . . . . . . . . . . 3-83. Install Rear Wall Sections . . . . . . . . . . . . . . . . . . . . 3-96. Finish Installing Backing Plates . . . . . . . . . . . . . . . 3-117. Install Front Wall Section . . . . . . . . . . . . . . . . . . . 3-118. Install Roof Panel . . . . . . . . . . . . . . . . . . . . . . . . 3-119. Install Burner Mounting Plate . . . . . . . . . . . . . . . . 3-1210a. Install Seal Ring [steam units] . . . . . . . . . . . . . . 3-1210b. Install Lift Lug Cover . . . . . . . . . . . . . . . . . . . . 3-1211. Seal weld end walls . . . . . . . . . . . . . . . . . . . . . . 3-1312. Install Drum Packing and Seal Plates . . . . . . . . . . 3-1413. Install 5th Pass Baffle . . . . . . . . . . . . . . . . . . . . . 3-1414. Install Insulation Under Tubes . . . . . . . . . . . . . . . 3-1515. Install Pass Insulation . . . . . . . . . . . . . . . . . . . . 3-1516. Prepare for Inner Casing Installation . . . . . . . . . . 3-1617. Prepare the Inner Casing Panels for . . . . . . . . . . 3-1718. Install Inner Casing . . . . . . . . . . . . . . . . . . . . . . 3-1819. Casing Pressure Test. . . . . . . . . . . . . . . . . . . . . . 3-1920. Install Outer Casing . . . . . . . . . . . . . . . . . . . . . . 3-21

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 high temperature sealant, supplied with the Model FLE assembly kit, is to be applied to the indicated areas before the panels are installed.

! DANGERCAUTION

Model FLE casing panels are shipped with insulation attached. Care must be taken when handling casing panels In order to prevent damage to the insulating materials.

! DANGERCAUTION

Careful attention must be given to the place-ment and integrity of casing joint gaskets and seals during assembly to ensure a tight seal. All casing joints must be completely sealed against leakage of combustion gas-es. Failure to ensure a tight seal at the joints may result in leakage of combustion gases and will cause damage to adjacent areas of the casing panels during operation of the boiler.

750-357 3-1

Casing Assembly Model FLE Assembly

Figure 3-1. Inner Casing, Steam

TOP VIEW

DETAIL A

A

5

4

14

8

3

96

22 18 21222118

1016

19

78

172019

12182112 18 21

7

7

2

7 7 7 7 8

7 7 7 7 5

27 24

2924

8 7 7 7 7 7 5

2824

25

23 242324

13

SECTION B-B B

B

F

E

GGH

H

33

30

33

32 32

33

31

33

30

33 30

36

36

35 35

APPLY A BEAD OF SILICONE TO BAFFLE SEAM

SEE NOTE #12

SEE NOTE #9

SEE NOTE #12

SEE NOTE #7

SEE NOTE #7

SEE NOTE #5

SEE NOTES #2 & #3

INSTALL PYRO-BLOC IN TURNAROUNDSECTION ONLY OF FOURTH PASS

NOTES:1) USE ITEM #34 TO FILL VOIDS.2) WRAP EXPOSED PORTION OF VENT TUBE AT REAR WALL.3) INSULATE UPPER PORTION OF LOWER DRUM, COVERING FERRULES AND RETAINING PLATES, INSULATION MUST EXTEND A MIN. OF 1/2" PAST FILLET WELDS ON FERRULES.4) TO SEAL AROUND DRUMS, PACK OPENING WITH B NAL KET STRIPS, PUMPABLE CERAWOOL (ITEM #34), AND APPLY AN OUTER LAYER OF SILICONE CAULK PRIOR TO INSTALLING COLLAR PLATE.5) FIT INSULATION UNDER BOILER TUBING (ITEM #32).6) PACK INSULATION UNDER VENT TUBE TO FILL VOIDS BETWEEN REAR WALL AND NEXT TUBE.

7) SPRAY ADHESIVE ON TUBES ABOVE AND BELOW PASS OPENINGS. APPLY INSULATION (ITEM #33) WITH RIGIDIZER (BLUE) TO INSIDE TO COVER PASS OPENINGS.8) INSULATION MUST OVERLAP AND COMPRESS AT ALL CORNERS.9) TRIM PYRO-LOGS (ITEM #30) TO FIT. USE TRIMMINGS TO PACK PYRO-LOGS TIGHT INTO TURNAROUND OPENINGS ON BOTH SIDES.10) LINE ENTIRE SECOND PASS WITH PYRO-LOG (ITEM #30).11) SPRAY ADHESIVE ON LOWER VERTICAL PORTION OF FURNACE PASS TUBES. APPLY INSULATION (ITEM #33) ALONG ENTIRE LENGTH OF FURNACE.12) INSULATE EXPOSED STEEL (ITEM #35) WITH PUMPABLE CERAWOOL (ITEM #34).

3-2 750-357


Figure 3-2. Inner Casing, Steam (cont’d)

DETAIL D

DETAIL FBAFFLE DETAIL

DETAIL EEND WALL CORNER PIECE DETAIL

24

23

19 26

19

11

ENSURE BAFFLE INSULATIONCOMPRESSES AGAINST DRUM

APPLY PTFE GASKET TAPE TO SEAMS

ENSURE BAFFLE INSULATION COMPRESSESAGAINST SIDE CASING INSULATION

APPLY A BEAD OF SILICONE TOHORIZONTAL AND VERTICAL SEAMS

BEFORE INSTALLING MOUNTING PLATES

APPLY TWO LAYERS OF PTFE GASKET TAPETO HORZONTAL AND VERTICAL SEAMS

22

6

4

750-357 3-3


3-4 750-357

Table 3-1: Inner casing parts, Steam

1250 1450 1650 1850 2100 2500

ITEM DESCRIPTION PART # QTY PART # QTY PART # QTY PART # QTY PART # QTY PART # QTY

1 GASKET, EXPANDED PTFE 032-02560 260 FT 032-02560 270 FT 032-02560 290 FT 032-02560 300 FT 032-02560 350 FT 032-02560 395 FT

2 BASE, ASSEMBLY 003-02522 1 003-02627 1 003-02635 1 003-02637 1 003-02526 1 003-02543 1

3 END WALL ASSEMBLY, REAR, LOWER

105-11929 1 105-11929 1 105-12129 1 105-12129 1 105-12086 1 105-12086 1

4 END WALL ASSEMBLY, FRONT, LOWER

105-11930 1 105-11930 1 105-12130 1 105-12130 1 105-12085 1 105-12085 1

5 CASING PANEL, INNER, SIDE, FRONT & REAR

105-11931 2 105-12171 2 105-12131 2 105-12244 2 105-12080 2 105-12076 2

6 END WALL ASSEMBLY, FRONT, UPPER

105-12200 1 105-12200 1 105-12263 1 105-12263 1 105-12214 1 105-12214 1

6 END WALL ASS’Y, FRONT, UPPER, w/FGR

105-11932 1 105-11932 1 105-12132 1 105-12132 1 105-12104 1 105-12104 1

7 CASING PANEL, INNER, SIDE 105-11933 6 105-11933 6 105-12133 8 105-12133 8 105-12082 8 105-12082 10

8 CASING PANEL, INNER, SIDE, FRONT & REAR

105-11934 2 105-12172 2 105-12134 2 105-12245 2 105-12081 2 105-12077 2

9 END WALL ASSEMBLY, REAR, UPPER

105-11954 1 105-11954 1 105-12139 1 105-12139 1 105-12087 1 105-12087 1

10 REAR END WALL ACCESS PANEL 105-12165 1 105-12165 1 105-12165 1 105-12165 1 105-12165 1 105-12165 1

11 CASING, BAFFLE, FIFTH PASS 105-12009 4 105-12010 4 105-12138 4 105-12141 4 105-12089 4 105-12183 4

12 MOUNTING PLATE 105-12189 2 105-12189 2 105-12346 2 105-12346 2 105-12189 2 105-12189 2

13 INNER CASING SPACER BLOCK 315-01336 16 315-01336 16 315-01336 20 315-01336 20 315-01336 20 315-01336 24

14 SIGHT PORT ASSEMBLY 550-00042 1 550-00042 1 550-00042 1 550-00042 1 550-00042 1 550-00042 1

15 NEVER-SEEZ, 16 OZ. CAN 797-01816 1 797-01816 1 797-01816 1 797-01816 1 797-01816 1 797-01816 1

16 ROPE, FIBERGLASS 853-00996 5 FT 853-00996 5 FT 853-00996 5 FT 853-00996 5 FT 853-00996 5 FT 853-00996 5 FT

17 CAPSCREW, 3/8-16 UNC 868-00056 136 868-00056 136 868-00056 180 868-00056 180 868-00056 220 868-00056 264

18 NUT, HEX HD, 1/2"-13 UNC 869-00144 32 869-00144 32 869-00144 36 869-00144 36 869-00144 44 869-00144 44

19 LOCKNUT, 3/8"-16 UNC 869-00510 385 869-00510 394 869-00510 464 869-00510 488 869-00510 546 869-00510 640

20 WASHER, FLAT, 3/8” 952-00106 136 952-00106 136 952-00106 180 952-00106 180 952-00106 221 952-00106 264

21 WASHER, FLAT, 1/2” 952-00286 32 952-00286 32 952-00286 36 952-00286 36 952-00286 44 952-00286 44

22 MOUNTING PLATE 315-01143 2 315-01143 2 315-01143 2 315-01143 2 315-01397 2 315-01397 2

23 SEALING PLATE, LOWER, OUTER 105-12443 2 105-12443 2 105-12443 2 105-12443 2 105-12447 2 105-12447 2

24 SCREW, SELF TAPPING, 1/4” 841-00423 48 841-00423 48 841-00423 48 841-00423 48 841-00423 48 841-00423 48

25 ROOF ASSEMBLY 105-12451 1 105-12458 1 105-12469 1 105-12472 1 105-12480 1 105-12486 1

26 BRACKET, BAFFLE, FIFTH PASS 105-12452 4 105-12459 4 105-12470 4 105-12474 4 105-12481 4 105-12487 4

27 PLATE, COVER, LUG, LIFTING 315-01099 2 315-01099 2 315-01099 2 315-01099 2 315-01099 2 315-01099 2

28 RING, STEAM OUTLET SEAL 105-12453 1 105-12453 1 105-12453 1 105-12473 1 105-12473 1 105-12473 1

29 PLATE, COLLAR, UPPER, OUTER 105-12454 2 105-12454 2 105-12454 2 105-12454 2 105-12483 2 105-12483 2

30 PYRO-LOG 872-00911 14 872-00911 16 872-00911 16 872-00911 17 872-00911 22 872-00911 24

31 INSULATION, WET PACK 872-00782 5 872-00782 6 872-00782 6 872-00782 7 872-00782 7 872-00782 8

32 INSULATION BLANKET 1-1/2” 2400 deg F

SEE TABLE

33 INSULATION BLANKET 1-1/2” 2400 deg F

SEE TABLE

34 PUMPABLE CERAWOOL 094-00474 8 LB 094-00474 8 LB 094-00474 8 LB 094-00474 8 LB 094-00474 10 LB 094-00474 10 LB

35 RETAINING PLATE, LOWER, INNER 105-12332 4 105-12332 4 105-12332 4 105-12332 4 105-12327 4 105-12327 4

36 PLATE, COLLAR, UPPER, INNER 105-12455 2 105-12455 2 105-12455 2 105-12455 2 105-12482 2 105-12482 2

ITEM QTY PART # 1250 1450 1650 1850 2100 2500

32 4 872-00500 1-1/2" x 6" x 142" LG 1-1/2" x 6" x 157" LG 1-1/2" x 8" x 172" LG 1-1/2" x 8" x 186" LG 1-1/2" x 11" x 200" LG 1-1/2" x 11" x 230" LG

33 2 872-00500 1-1/2" x 24" x 142" LG 1-1/2" x 24" x 157" LG 1-1/2" x 24" x 172" LG 1-1/2" x 24" x 186" LG 1-1/2" x 24" x 200" LG 1-1/2" x 24" x 230" LG

750

-357

3-5

Figure 3-2. Inner Casing, Hot Water

DETAIL A

A

8 9 9 9 7

10

13 182622

8 9 9 9 7

89997

27 18

26 212126

1 15

45

6

14

2622

27 18

11

22 26

319

23

16

12

23 20 25

2

NOTE:1) ALL GASKET SURFACES TO BE A MAXIMUM OF 1/16" OUT OF FLATNESS OVER ANY 2 FT. LENGTH.2) ALL ALIGNMENTS TO BE WITHIN 1/8".3) APPLY ITEM #2 TO ALL CASING SEAMS.4) APPLY SILICONE AT GAPS BETWEEN BASE ANGLE AND END WALL.5) APPLY GASKET TO BOILER IN SINGLE PIECE. NO SEAMS ALLOWED ON BASE OR END WALLS.6) APPLY SMALL AMOUNT OF TEFLON PASTE (ITEM #24) AT POINTS WHERE VERTICAL GASKETS OVERLAP WITH HORIZONTAL GASKETS PROIR TO INSTALLING PANELS.7) APPLY "NEVER-SEEZ" (ITEM #17) TO INNER CASING STUDS AND BOLTS PRIOR TO INSTALLING NUTS AND WASHERS.8) APPLY PUMPABLE IN CORNER BEFORE INSTALLING SIDE WALLS.

3-67

50-3

57

Figure 3-2. Inner Casing, Hot Water (cont’d)

SECTION B-B

DETAIL C

B

B

NOTES:1) USE ITEM #32 TO FILL VOIDS.2) WRAP EXPOSED PORTION OF VENT TUBE AT REAR WALL.3) INSULATE UPPER PORTION OF LOWER DRUM, COVERING FERRULES AND RETAINING PLATES, INSULATION MUST EXTEND A MIN. OF 1/2" PAST FILLET WELDS ON FERRULES.4) TO SEAL AROUND UPPER DRUM, PACK OPENING WITH BALNKET STRIPS, PUMPABLE CERAWOOL (ITEM #32), AND APPLY AN OUTER LAYER OF SILICONE CAULK PRIOR TO INSTALLING COLLAR PLATE.5) FIT INSULATION UNDER BOILER TUBING (ITEM #29).6) PACK INSULATION UNDER VENT TUBE TO FILL VOIDS BETWEEN REAR WALL AND NEXT TUBE.7) FILL VOID AROUND LOWER DRUM WITH PUMPAB EL CERAWOOL (ITEM #32).

9) SPRAY ADHESIVE ON TUBES ABOVE AND BELOW PASS OPENINGS. APPLY INSULATION WITH RIGIDIZER (BLUE) TO INSIDE TO COVER

PASS OPENINGS.10) INSULATION MUST OVERLAP AND COMPRESS AT ALL CORNERS.11) TRIM PYRO-LOGS (ITEM #31) TO FIT. USE TRIMMINGS TO PACK PYRO-LOGS TIGHT INTO TURNAROUND OPENINGS ON BOTH SIDES.12) LINE ENTIRE SECOND PASS WITH PYRO-LOG (ITEM #31).13) PACK INSUALTION AROUND LIFT LUGS. PLACE BEAD OF SILICONE AROUND THE LUG ON INSIDE EDGE OF ROOF PRIOR TO INSTALLING COVER.

28

2929

31

31

30

30 INSTALL PYRO-LOG IN TURNAROUNDSECTION ONLY OF FOURTH PASS

INSTALL PYRO-LOG ENTIRELENGTH OF SECOND PASS

3130

SEE NOTE #9

SEE NOTE #9

SEE NOTES #2 AND #3

SEE NOTE #11

34

TACKBOTH SIDES

35

35

3333

8) INSULATE COMBUSTION SIDE OF LOWER DRUM INNER RETAININGPLATES WITH PUMPABLE CERAWOOL.

750

-357

3-7

Table 3-2: Inner casing parts, Hot Water1250 1450 1650 1850 2100 2500

ITEM DESCRIPTION PART # QTY PART # QTY PART # QTY PART # QTY PART # QTY PART # QTY1 BASE ASSEMBLY 003-02522 1 003-02527 1 003-02635 1 003-02637 1 003-02526 1 003-02543 12 GASKET, PTFE 032-02560 218’ 032-02560 225’ 032-02560 250’ 032-02560 255’ 032-02560 260’ 032-02560 290’3 REAR END WALL ACCESS PANEL 105-12165 1 105-12165 1 105-12165 1 105-12165 1 105-12165 1 105-12165 14 END WALL ASSEMBLY, FRONT 15 END WALL ASSEMBLY, REAR, LOWER 105-12204 1 105-12204 1 105-12365 1 105-12365 1 105-12223 1 105-12223 16 END WALL ASSEMBLY, REAR, UPPER 105-12205 1 105-12205 1 105-12366 1 105-12366 1 105-12224 1 105-12224 17 CASING PANEL, INNER, SIDE, FRONT AND REAR 105-12206 2 105-12209 2 105-12367 2 105-12375 2 105-12225 2 105-12257 28 CASING PANEL, INNER, SIDE, FRONT AND REAR 105-12207 2 105-12210 2 105-12368 2 105-12376 2 105-12226 2 105-12258 29 CASING PANEL, INNER, SIDE 105-12208 6 105-12208 6 105-12369 8 105-12369 8 105-12228 8 105-12228 10

10 ROOF ASSEMBLY 105-12211 1 105-12231 1 105-12370 1 105-12377 1 105-12232 1 105-12259 111 MOUNTING PLATE 105-12220 1 105-12220 1 105-12346 1 105-12346 1 105-12189 1 105-12189 112 ASSEMBLY, PRESSURE VESSEL 301-00115 1 301-00117 1 301-00140 1 301-00141 1 301-00116 1 301-00121 113 PLATE, COVER, LIFTING LUG 315-01099 2 315-01099 2 315-01099 2 315-01099 2 315-01099 2 315-01099 214 MOUNTING PLATE 315-01143 1 315-01143 1 315-01143 1 315-01143 1 315-01397 1 315-01397 115 INNER CASING SPACER BLOCK 315-01336 16 315-01336 16 315-01336 20 315-01336 20 315-01336 20 315-01336 2416 SIGHT PORT ASSEMBLY 550-00042 1 550-00042 1 550-00042 1 550-00042 1 550-00042 1 550-00042 117 NEVER-SEEZ, 16 OZ. CAN 797-01816 1 797-01816 1 797-01816 1 797-01816 1 797-01816 1 797-01816 118 SCREW, SELF TAPPING 841-00423 28 841-00423 28 841-00423 28 841-00423 28 841-00423 28 841-00423 2819 ROPE, FIBERGLASS 853-00996 1 853-00996 1 853-00996 1 853-00996 1 853-00996 1 853-00996 120 CAPSCREW, 3/8” 868-00056 112 868-00056 112 868-00056 160 868-00056 160 868-00056 190 868-00056 22821 CAPSCREW, HEX HD, 1/2” 868-00093 16 868-00093 16 868-00093 16 868-00093 16 868-00093 20 868-00093 2022 NUT, HEX HD 869-00144 24 869-00144 24 869-00144 28 869-00144 28 869-00144 34 869-00144 3423 LOCKNUT 869-00510 288 869-00510 296 869-00510 356 869-00510 364 869-00510 410 869-00510 47224 TEFLON PASTE PIPE DOPE 887-00035 1 887-00035 1 887-00035 1 887-00035 1 887-00035 1 887-00035 125 WASHER, FLAT, 3/8” 952-00106 112 952-00106 112 952-00106 160 952-00106 160 952-00106 190 952-00106 22826 WASHER, FLAT, 1/2” 952-00286 41 952-00286 41 952-00286 45 952-00286 45 952-00286 55 952-00286 5527 PLATE, COLLAR, UPPER, OUTER 315-01210 2 315-01210 2 105-12371 2 105-12371 2 105-12233 2 105-12233 228 INSULATION, WET PACK 872-00782 5 872-00782 6 872-00782 6 872-00782 5 872-00782 7 872-00782 829 INSULATION BLANKET 1-1/2” 2400 deg F

See table30 INSULATION BLANKET 1/2” 2300 deg F31 PYRO-LOG 872-00911 14 872-00911 16 872-00911 16 872-00911 17 872-00911 22 872-00911 2432 PUMPABLE CERAWOOL 094-00474 40 LB 094-00474 40 LB 094-00474 44 LB 094-00474 44 LB 094-00474 56 LB 094-00474 56 LB33 RETAINING PLATE, LOWER, INNER 105-12332 4 105-12332 4 105-12332 4 105-12332 4 105-12332 4 105-12327 434 SEALING PLATE, LOWER DRUM 105-12324 2 105-12324 2 105-12324 2 105-12324 2 105-12297 2 105-12297 235 PLATE, COLLAR, UPPER, INNER 315-01183 2 315-01183 2 105-12372 2 105-12372 2 105-12227 2 105-12227 2

ITEM QTY PART # 1250 1450 1650 1850 2100 250029 4 872-00500 1 1/2" x 5" x 142" LG 1 1/2" x 5" x 157" LG 1 1/2" x 8" x 186" LG 1 1/2" x 8" x 186" LG 1 1/2" x 11" x 200" LG 1 1/2" x 10" x 230" LG30 2 872-00895 1/2" x 18" x 142" LG 1/2" x 18" x 157" LG 1/2" x 24" x 186" LG 1/2" x 24" x 186" LG 1/2" x 24" x 200" LG 1/2" x 24" x 230" LG


Figure 3-3. Location of Vent Tube

Figure 3-4. Wetpack on vent tube

Figure 3-5. Positioning insulation over the ferrules

Figure 3-6. Wetpack on lower drum and vent tube.

1. Install Wetpack around Vent Tube and Lower Drum• Position a length of wetpack over the internal portion

of the tube to determine its length. Cut it to fit the tube. Tightly wrap the tube with the wetpack and tape (with masking or duct tape) it in place. Push the wetpack between the adjacent tubes through the external bend of the vent tube. The joint should face rear (Figure 3-4).

• 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 3-5).

• 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 3-6).

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.

• The wetpack should be positioned to be level with, or just outside the base refractory at the front.

2. Install Backing Plates

Remove Support Bracket

• Remove the drum spreader• Torch the support bracket to remove it from the upper

drum. Leave at least ½” of the bracket; DO NOT cut into the 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-ing plate seams are in a vertical position around the upper drum (Figure 3-7).

Vent Tube

Rear View

3-8 750-357


Figure 3-7. Installing Backing Plate on Upper Drum

Figure 3-8. Backing Plate on Lower Drum

Figure 3-9. Packing the Insulation

Figure 3-10. Placing Wall Section

Lower Backing Plate

• Install the retaining ring segments on the base around the lower drum. (Figure 3-8).

3. Install Rear Wall Sections• After checking that the insulation is packed (Figure

3-9), lift the large piece of the rear wall into position (Figure 3-10). Until the wall is in the correct vertical position, leave a gap between the tubes and the wall to keep the insulation from getting compressed. Set the wall section on top of the base.

• Wedge the wall upright.• Once the wall is in the correct vertical position,

wedge wall into tubes so the Pyro-Bloc compresses against tubes.

• Check that the sides of the wall line up with the base angles. If the wall will not line up exactly, then center the wall in relation to the base angles.

• Once in place, install angle brackets to temporarily secure end wall.

•

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 3-11. Align wall with base angle

1. Move the corner section of the rear wall into position taking care not to let the insulation get caught in the

750-357 3-9


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.

3- 14

Figure 3-12. Rear wall

Figure 3-13. Use bar clamps and wedges to align wall

Figure 3-14. Insulation in the gaps

2. 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 3-13).

3. Make sure that the walls are flush with each other and secure all of the bolts.

4. Remove the clamps.5. 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 3-14). 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.

LOCATION OF GASKET

LOCATION OF GASKET

3-10 750-357


Figure 3-15. Finishing the wetpack insulation installation

Figure 3-16. Packing the top of the walls

Figure 3-17. Filling the joint with silicone caulking

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.

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).

• Fill any joints in the top of the front and rear walls with silicone caulking.

• Apply PTFE gasket strip along width of front and rear end wall (Figure 3-18). Apply high-temp silicone to seams.

• In the roof, cut the holes for the lift lugs. 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 3-18. PTFE gasket strip on the top of the front and rear walls

750-357 3-11


Figure 3-19. Attaching the Roof to the Front Wall

9. Install Burner Mounting Plate

• Trim the insulation on the inside of the boiler at a 45º angle (Figure 3-20).

• Pack any gaps in the insulation.

• Using spray adhesive, install the rope gasket on the front wall inside the bolt pattern. The gasket should wrap around the opening twice.

• Lift the mounting plate and bolt in place. Check the insulation. The insulation should be tight around the mounting plate.

• 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 in the insulation.

Figure 3-20. Cutting Insulation from the Burner Door

10a. Install Seal Ring [steam units]

• Pack insulation around steam outlet.

• Place a bead of silicone around the outlet on the inside edge of the roof and install steam outlet seal ring.

10b. Install Lift Lug Cover• Using the insulation trimmed from step 8, fill the gap

between the lift lug and the insulation.

• Pack any gaps in the insulation (Figure 3-21).

• Place a bead of silicone around the lug and on the inside edge of the roof (Figure 3-22).

• 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 3-23).

• Use a putty knife and clean the surface of the cover (Figure 3-24).

Figure 3-21. Filling the Gaps with InsulationPYRO-BLOC TO BE PUSHED TIGHTAGAINST BURNER SUPPORT PLATE

PYRO-BLOC

REFRACTORY

BURNER SUPPORT PLATE

3-12 750-357


Figure 3-22. Silicone around the Lifting Lug

Figure 3-23. Tightening the cover

Figure 3-24. Cleaning excess silicone from the lid

11. Seal weld end walls

Seal weld bottom of front and rear end walls to base (Figure 3-25).

G

2X

2X

USE TO HOLD END WALL IN PLACE.TACK WELD END WALL IN PLACE, THENREMOVE AND COMPLETE WELD.BRACKET

BRACKET

Figure 3-25. Weld end wall

750-357 3-13


Figure 3-28. Secure Cover Plates

12. Install Drum Packing and Seal Plates

• Pack LDS moldable insulation (872-680) around the upper, front and rear drums to fill the void. Push it in toward the backing plate, com-pressing the insulation tightly. The insulation should be packed to within 1" of the outer wall.

NOTE: Use the excess pyrobloc from the cutoutof the burner door to pack around the drums.

• Apply a layer of silicone caulk (872-420) to drum wall opening.

• Install the drum seal cover plates and secure them with the self-tapping screws (841-00423).

13. Install 5th Pass Baffle

Install the left and right side 5th pass baffle casing (2 pieces each side). See Figure 3-29.

• Apply PTFE gasket tape to seams A.• Ensure baffle insulation compresses against the drum

B and against the side casing insulation C.• Apply a bead of silicone to the baffle seam D.

Figure 3-29. 5th Pass Baffle

Figure 3-26. Pack insulation in drum wall opening

Figure 3-27. Caulk and silicone drum wall opening

A

A

B C

D

3-14 750-357


Figure 3-30. Insulation detail

14. 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. 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 (872-500) below the boiler tubes, on top of the refractory running the full length of the boiler.

• Install 24" wide by 1-1/2" thick insulation along entire length of boiler on top of refractory. Use a spray adhesive to hold the insulation in place (Figure 3-30).

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 equipment failure or unsafe operation.

! DANGERWARNING

15. Install Pass Insulation• Line entire second pass with Pyro-log.• Pack Pyro-logs into 2nd and 4th pass turnaround

openings.• Spray adhesive (94-475) on the tubes above and

below the 2nd and 4th pass opening. Install a 24" wide piece of 1-1/2” thick blanket insulation onto the entire side of the tubes and pyro-log, pressing it onto the adhesive. Trim any excess blanket at the end (Figure 3-31).

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 3-31. Insulation along Pass Opening

E

SEE NOTES #2 AND #3

SEE NOTE #7

SEE NOTE #7INSTALL PYRO-LOG IN TURNAROUNDSECTION ONLY OF FOURTH PASS

INSTALL PYRO-LOG ENTIRELENGTH OF SECOND PASS

SEE NOTE #9

NOTES:1) USE ITEM #35 TO FILL VOIDS.2) WRAP EXPOSED PORTION OF VENT TUBE AT REAR WALL.3) INSULATE UPPER PORTION OF LOWER DRUM, COVERING FERRULES AND RETAINING PLATES, INSULATION MUST EXTEND A MIN. OF 1/2" PAST FILLET WELDS ON FERRULES.4) TO SEAL AROUND DRUMS, PACK OPENING WITH BALNKET STRIPS, PUMPABLE CERAWOOL (ITEM #35), AND APPLY AN OUTER LAYER OF SILICONE CAULK PRIOR TO INSTALLING COLLAR PLATE.5) FIT INSULATION UNDER BOILER TUBING (ITEM #33).6) PACK INSULATION UNDER VENT TUBE TO FILL VOIDS BETWEEN REAR WALL AND NEXT TUBE.

7) SPRAY ADHESIVE ON TUBES ABOVE AND BELOW PASS OPENINGS. APPLY INSULATION (ITEM #34) WITH RIGIDIZER (BLUE) TO INSIDE TO COVER PASS OPENINGS.8) INSULATION MUST OVERLAP AND COMPRESS AT ALL CORNERS.9) TRIM PYRO-LOGS (ITEM #31) TO FIT. USE TRIMMINGS TO PACK PYRO-LOGS TIGHT INTO TURNAROUND OPENINGS ON BOTH SIDES.10) LINE ENTIRE SECOND PASS WITH PYRO-LOG (ITEM #31).11) SPRAY ADHESIVE ON LOWER VERTICAL PORTION OF FURNACE PASS TUBES. APPLY INSULATION (ITEM #34) ALONG ENTIRE LENGTH OF FURNACE.12) INSULATE EXPOSED STEEL (ITEM #36) WITH PUMPABLE CERAWOOL (ITEM #35).

APPLY A BEAD OF SILICONE TO BAFFLE SEAM

ENSURE BAFFLE INSULATION COMPRESSESAGAINST SIDE CASING INSULATION

SEE NOTE #5

BLANKET

BLANKET

BLANKET

BLANKET

BLANKET

PYRO-LOG

PYRO-LOG

WET PACK

BLANKET

PYRO-LOG

750-357 3-15


Figure 3-32. Trimming the excess gasket and wiping the sealing surface

Figure 3-33. Silicone around the gasket at the seam between the roof and the wall

Figure 3-34. Gasket positioned 1/8" from the inside

16. 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.

• Apply silicone caulk (872-420) to the seam between the roof and the end wall.

• Use extra pieces 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.

• Apply the expanded PTFE gasket (32-2560) to the boiler. The gasket should be positioned approxi-mately 1/8" from the inside edge of the frame. Start at the front of the roof 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. The gas-ket has an adhesive strip attached; however, a spray adhesive may be used to hold the gasket in place.

Figure 3-35. Gasket starts at the roof

Figure 3-36. Gasket Ends at the roof in a tight seal

3-16 750-357


Figure 3-37. Insulation on the side Panel after packing

Figure 3-38. Top Gasket Placement on the Side Panel

Figure 3-39. Gasket Placement on the Side of the Side Panel

17. 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.

• Place a gasket on the side of the panel. It should go the full height of the panel from the top to the bot-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.

Figure 3-40. Gasket on the inner panels

Figure 3-41. Gasket on the inner panels

750-357 3-17


18. 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 14. Try not to let the insulation touch the boiler until it is in its resting position.

• The inner casing panels are to be oriented with the lift eyes at the top.

• Panels should be installed starting in the middle. Place the 1st (middle) panel on the base. Install a washer and place the nuts (several turns) on the 2nd and 4th stud. Repeat this at the top of the panel.

• Using the silicone, seal the seam of the gaskets at the top and bottom of the center panel.

• 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.

• 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.

• 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 228 in-lb.

Repeat these steps on the other side of the boiler.

Figure 3-42. Lifting the panels into position, taking care not to touch the insulation

Figure 3-43. Sealing the seam between the gaskets

Figure 3-44. Tightening the bolts connecting the panels

The panel bolts should be tightened to a torque of 228 in-lb. Do not over-tighten.

! DANGERWARNING

3-18 750-357


19. Casing Pressure Test

This test procedure is to be performed on all FLE units. The test is to be performed after installation of the casing inner panels, burner door, and all seal plates. Test to be performed prior to installation of burner, gas train and water columns.

1. Blank the burner mounting flange with plate, seal as required. Blank FGR opening if applicable.

2. Tap the burner plate and install a pressure gage or manometer with a range up to 9" WC.

3. Cover the stack opening using cover plates and seal with gasket and clamps.

4. Install an air supply and air flowmeter to the sight port in the rear of the boiler. Typical arrangement is shown in Figure 1. Plant air may be used if properly regulated or a separate air pump of proper pressure and flow is required.

Figure 3-45. Air supply and flowmeter

5. With the bypass around the flow meter closed, slowly open the valve downstream of the air pump or plant air to introduce air through the flow meter. The valve only needs to be opened very slightly at first. Pressur-ize the boiler to 5" WC using the pressure gauge located on the boiler to determine the pressure in the boiler. Care must be taken not to over pressurize the casing, particularly when using plant air. Allow the pressure to stabilize at 5" WC If unable to achieve the required pressure, open the bypass slowly to attempt to achieve as close to 5" WC as possible and proceed to corrective measures below.

6. Using Table 3-3 below, verify the air flowmeter indi-

cates a reading at or below the Maximum limit. If the flow rate exceeds the maximum permitted, proceed to corrective actions below. Upon achieving a suc-cessful flow rate at the specified test pressure, record flow rate during test and document on the Flextube Air Test Report. File the Flextube Air Test Report along with the Boiler Startup Report.

Corrective Measures

If the flow rate does not pass the specified rate at the initial test, soap test casing joints and mark where significant leaks are occurring. Where leaks occur, casing panels are to be removed and gasket-ing surfaces are to be examined. Reinstall inner side casing with double gasketing where possible. Caulk thoroughly with high temp RTV sealant. Add ample high temp sealant where joints meet.

Examine seams between wall sections. If significant leakage is occurring in this area, gouge out Kaowool gasket in seams between the two parts and fill with high temp sealant with steps of ¼” rope gasket (Fig. 3-46).

After correcting leaking areas, repeat the air test above until successful.

750-357 3-19


Figure 3-46. Wall seam repair

Table 3-3: Pressure Test

Boiler Vessel Size Test Pressure (W.C.) Maximum Flow (CFM) Maximum Flow (CFH)

1250 5.0 11.77 706

1450 5.0 13.63 818

1650 5.0 15.53 932

1850 5.0 17.39 1043

2100 5.0 19.77 1182

2500 5.0 23.54 1412

3-20 750-357


20. Install Outer Casing• Stick the approximately 2” square pieces of foam

insulation 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 place-ment locations.

• Install the outer casing top corner pieces. The pieces overlap where they are joined.

Figure 3-47. Outer casing top corners

• Install the outer casing panels by sliding the top under the top corner 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.

• 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 top corner panels.

• Position the side corner casings and secure them to the end walls and roof casing.

750-357 3-21


3-22 750-357

Outer Casing Steam

4 2 2 2 2 2 1 3 636

5

5

56

56

1250 1450 1650 1850 2100 2500

ITEM DESCRIPTION PART # QTY PART # QTY PART # QTY PART # QTY PART # QTY PART # QTY

1 CASING PANEL, OUTER SIDE, REAR - - 105-11944 2 - - - - - - 105-12186 2

2 CASING PANEL, OUTER SIDE, MIDDLE 105-11942 8 105-11942 6 105-12151 10 105-12151 10 105-12064 10 105-12064 10

3 OUTER CASING, SIDE CORNER 105-12456 4 105-12456 4 105-12471 4 105-12471 4 105-12488 4 105-12488 4

4 CASING PANEL, OUTER SIDE, FRONT 105-12022 2 105-12169 2 105-12159 2 105-12241 2 105-12062 2 105-12185 2

5 OUTER CASING, TOP CORNER 105-12219 4 105-12260 4 105-12361 4 105-12374 4 105-12253 4 105-12261 4

6 SCREW, SELF TAPPING 841-00423 24 841-00423 24 841-00423 24 841-00423 24 841-00423 24 841-00423 24

3-23

750

-35

7

Outer Casing HW1250 1450 1650 1850 2100 2500

ITEM DESCRIPTION PART # QTY PART # QTY PART # QTY PART # QTY PART # QTY PART # QTY1 CASING PANEL, OUTER SIDE, REAR - - 105-12326 1 - - - - - - 105-12341 12 CASING PANEL, OUTER SIDE, MIDDLE 105-12217 8 105-12217 6 105-12360 10 105-12360 10 105-12252 10 105-12252 103 OUTER CASING, SIDE CORNER 315-01187 4 315-01187 4 105-12362 4 105-12362 4 105-12254 4 105-12254 44 CASING PANEL, OUTER SIDE, FRONT 105-12216 2 105-12229 2 105-12359 2 105-12373 2 105-12251 2 105-12260 25 OUTER CASING, TOP CORNER 105-12219 4 105-12230 4 105-12361 4 105-12374 4 105-12253 4 105-12261 46 SCREW, SELF TAPPING 841-00423 24 841-00423 24 841-00423 24 841-00423 24 841-00423 24 841-00423 24

SECTION A-A DETAIL C

DETAIL B

DETAIL D

A

A

C

B

D

5 6 5 636 3 6

5 5

55

5

6

6

NOTE: PART #3 IS MEANT TO OVERLAP

2 2 222 14


3-24 750-357

Model FLE Assembly Burner Installation

CHAPTER 4Burner Installation

1. Burner Mounting . . . . . . . . . . . . . . . . . . . 4-12. Gas System . . . . . . . . . . . . . . . . . . . . . . . 4-13. Oil System . . . . . . . . . . . . . . . . . . . . . . . . 4-34. Electrical Connections and Layout . . . . . . . . 4-45. FGR System (Low NOx applications) . . . . . . 4-4

1. Burner MountingThe burner is designed for operation with the blast tube level. Do not tilt the burner up or excessively downward. Allow enough clearance at the rear of the burner to allow the housing to swing open for service and maintenance.

The burner mounting flange is designed to provide for a seal. The face of the boiler and burner flange must be sealed with a rope gasket (not supplied with the burner). Make sure the dry oven and burner blast tube are concentric.

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

2. Gas System

Gas is introduced into the combustion zone from a circular manifold through multiple ports in the manifold. Firing rate is determined by the size and number of ports, by manifold pressure, and by combustion zone pressure. The firing rate is regulated by a rotary, butterfly-type throttling valve at the manifold inlet. The valve is actuated by an adjustable linkage from the modulating motor. Depending upon specific requirements, one or two safety shutoff motorized main gas valves are provided for installation in the gas train upstream of the butterfly valve. Safety shutoff gas valves are wired into the programming control to automatically open and close at the proper time in the operating sequence.

Gas Piping

Gas service and house piping must supply the quantity of gas demanded by the unit at the pressure required at the burner gas train inlet. All piping must be in strict accordance with applicable codes, ordinances, and regulations of the supplying utility.

In the absence of other codes, piping should be in accordance with the following standards: National Fuel Gas Code NFPA No. 54, ANSI No. Z 223.1 (for Canada, the Canadian Gas Association (CGA) B149 and Canadian Standards Association (CSA) B140 codes shall prevail).

Gas train components upstream of the butterfly valve are shipped loose. These components should be mounted by the installer as close to the butterfly valve as practical. Normally, the control train is ordered to suit a particular code or insurance regulation, such as Underwriters Laboratories Inc., CGA, or Factory Mutual.

Arrange gas piping at the burner so that the burner is accessible for servicing without disassembly.

The gas pilot supply line must be connected upstream of the main gas regulator. If a reducing bushing is required between the house piping and the burner piping, it should be close to the burner shut-off valve.

The gas piping must be internally clean and free of foreign material. Before using in service, a leak test must be performed.

Check that all connections are tight following the completion of the gas train plumbing (components may have loosened or moved during shipping). Pressurize the gas train with 1 psig of air pressure and using a soapy water solution, either spray or brush the solution on all connections. If bubbles are evident, the suspected connection must be disassembled and checked for damage. After completing the inspection, seal, reassemble, and retest the connection.

750-357 4-1

Burner Installation Model FLE Assembly

Figure 4-1. Gas Train

BURNER SUPPORT DETAIL

DESCRIPTIONPART NO.QTYITEMSUPPORT, BURNER, EV-SERIESSEE TABLE11ASSEMBLY, FGR PIPINGSEE TABLE12BURNER-ASSEMBLY (DWG 829-3044-000)SEE TABLE13ROPE, FIBERGLASS, 1/2" DIA. 1000 DEG. HI-DENSITY853-00996-000"A"4CAPSCREW, HX HD, 1/2"-13UNC-2A X 1-1/2" LG.868-00102-00025CAPSCREW, HEX HD. 1/2-13 UNC x 2" LG. A307 GR. A868-00176-00026NUT, HEX HD. 1/2-13 UNC ASTM A563 GR. A869-00015-000"B"7WASHER, LOCK, 1/2" PLAIN STEEL952-00094-00048WASHER, FLAT, 1/2", PLAIN STEEL952-00286-000"C"9WASHER, BEVELED, 1-1/4" SQ. X 1/2" BOLT SIZE952-00376-000210

BURNER MODEL FORMATXXXX XX XXX

BURNER SERIES(EV, LNEV, NTEV) FUEL CODE BURNER SIZE

FUEL SERIES DESIGNATIONCB CODE DESCRIPTION IC CODE

100 LIGHT OIL L200 LIGHT OIL & GAS LG700 GAS ONLY G

1

2

3

1

4

59

789

69

7810

BASE END RAIL

BURNER SUPPORTPEDESTAL

DRY OVEN(SEE BURNER ASSEMBLY)

7

9

2

Figure 4-2. Burner Installation

PILOT GAS TRAIN

MAIN GAS TRAIN

Item Description1 Pilot manual shutoff cock2 Pilot gas pressure regulator3 Pilot safety shutoff valve (2)4 Pilot vent valve5 Safety shutoff valve6 Manual shutoff valve (2)7 Gas valve actuator with proof of closure 8 Gas valve regulating actuator9 Metering valve10 Low gas pressure switch11 High gas pressure switch12 Vent valve13 Pressure gauge (4)

4-2 750-357


3. Oil System

EV Series burners use compressed air for atomiza-tion. Atomizing air is independent of combustion air. The system is supplied with a separate compressor module for mounting near the burner.

Figure 4-3. Oil System

750-357 4-3

Burner Installation Model FLE Assembly

4. Electrical Connections and Layout

Use the wiring diagram supplied with the boiler for layout and wiring purposes.

5. FGR System (Low NOx applica-tions)

LNEV burners are equipped with an FGR (flue gas recirculation) valve to lower the NOx emissions. An actuator is provided to adjust the FGR valve position throughout the firing range on gas.

Figure 4-4. FGR system

4-4 750-357

Burner Installation

Mo

de

l FL

E A

ssem

bly

4-57

50-3

57

Figure 4-5. Nameplate locations, steam boiler

Model F

LE A

ssembly

Bu

rne

r Installation

750

-357

4-6

Figure 4-6. Nameplate locations, hot water boiler


750-357 4-7

e-mail: [email protected] Address: http://www.cleaverbrooks.com

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