D E S I G N E D
T O L E A D
Series 24
Forced Draft Steam or Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler.
Models:
• 24-03
• 24-04
• 24-05
• 24-06
• 24-07
• 24-08
• 24-09
• 24-10
• 24-11
• 24-12
WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, con-
sult a qualified installer, service agency or the gas supplier.
This boiler requires a special venting system. Read these
instructions carefully before installing.
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
IMPORTANT INFORMATION - READ CAREFULLY
All boilers must be installed in accordance with National, State and Local Plumbing,
Heating and Electrical Codes and the regulations of the serving utilities. These
Codes and Regulations may differ from this instruction manual. Authorities having
jurisdiction should be consulted before installations are made.
In all cases, reference should be made to the following Standards:
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil
Burning Equipment”, for recommended installation practices.
B. Current Edition of National Fuel Gas Code, NFPA 54/ANSI Z223.1.
C. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
D. Current Edition of American Society of Mechanical Engineers ASME CSD-1,
"Controls and Safety Devices for Automatically Fired Boilers", for assembly and
operations of controls and safety devices.
E. All wiring on boilers shall be made in accordance with the National Electrical
Code and/or Local Regulations.
DANGER
CAUTION
Indicates an imminently hazardous situation
which, if not avoided, will result in death,
serious injury or substantial property
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate
or minor injury or property damage.
damage.
NOTICE
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property
damage.
Indicates special instructions on installation,
operation, or maintenance which are
important but not related to personal injury
hazards.
DANGER
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any
other appliance.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property
damage, personal injury or loss of life. Failure to follow all instructions in the proper order
can cause personal injury or death. Read and understand all instructions, including all
those contained in component manufacturers manuals which are provided with the
appliance before installing, starting-up, operating, maintaining or servicing this appliance.
Keep this manual and literature in legible condition and posted near appliance for reference
by owner and service technician.
This boiler requires regular maintenance and service to operate safely. Follow the
instructions contained in this manual. Installation, maintenance, and service must be
performed only by an experienced, skilled and knowledgeable installer or service agency.
All heating systems should be designed by competent contractors and only persons
knowledgeable in the layout and installation of hydronic heating systems should attempt
installation of any boiler. It is the responsibility of the installing contractor to see that all
controls are correctly installed and are operating properly when the installation is
completed. Installation is not complete unless a pressure relief valve is installed into the
specified tapping located at the rear of appliance - See Section III of this manual for details.
This boiler is suitable for installation on combustible flooring. Do not install boiler on
carpeting. Do not operate on floors where heat affected material is below.
Do not tamper with or alter the boiler or controls. Retain your contractor or a competent
serviceman to assure that the unit is properly adjusted and maintained.
Clean boiler at least once a year - preferably at the start of the heating season to remove
soot and scale. The inside of combustion chamber should also be cleaned and inspected
at the same time.
Have Burner and Controls checked at least once a year or as may be necessitated.
Do not operate unit with jumpered or absent controls or safety devices.
Do not operate unit if any control, switch, component, or device has been subject to water.
Return water cannot be lower than 135°F for prolonged periods of time. Operation under
these conditions will result in sustained condensing within the combustion chamber and
potentially reduce boiler longevity.
In addition, the return water cannot be introduced into the boiler if it is more than 40°F less
than the idle boiler temperature. Continued operation under these conditions may result in
premature boiler failure through thermal shock.
Example: A boiler that has been idle for some time since the last heat demand cycle may
have it's boiler water temperature reduced to 150°F. The return temperature from the next
zone activation cannot be less than 110°F.
If the above conditions exist, an RTC system must be installed to protect the boiler from
sustained condensing operation and thermal shock.
WARNING
Appliance materials of construction, products of combustion and the fuel contain alumina,
silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or
harmful substances which can cause death or serious injury and which are known to the
state of California to cause cancer, birth defects and other reproductive harm. Always use
proper safety clothing, respirators and equipment when servicing or working nearby the
appliance.
This boiler contains very hot water or steam under high pressures. Do not unscrew any
pipe fittings nor attempt to disconnect any components of this boiler without positively
assuring the water is cool and has no pressure. Always wear protective clothing and
equipment when installing, starting up or servicing this boiler to prevent scald injuries. Do
not rely on the pressure and temperature gauges to determine the temperature and pressure
of the boiler. This boiler contains components which become very hot when the boiler is
operating. Do not touch any components unless they are cool.
This appliance must be properly vented and connected to an approved vent system in good
condition. Do not operate boiler with the absence of an approved vent system.
This boiler needs fresh air for safe operation and must be installed so there are provisions
for adequate combustion and ventilation air.
The interior of the venting and air intake systems must be inspected and cleaned before the
start of the heating season and should be inspected periodically throughout the heating
season for any obstructions. Clean and unobstructed venting and air intake systems are
necessary to allow noxious fumes that could cause injury or loss of life to vent safely and
will contribute toward maintaining the boiler's efficiency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-
start without service. If damage due to frozen pipes is a possibility, the heating system
should not be left unattended in cold weather; or appropriate safeguards and alarms should
be installed on the heating system to prevent damage if the boiler is inoperative.
This boiler is designed to burn No. 2 fuel oil, natural and/or LP gas only. Do not use
gasoline, crankcase drainings, or any oil containing gasoline. Never burn garbage or paper
in this boiler. Do not convert boiler to burn any solid fuel (i. e. wood, coal) . All flammable
debris, rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep
the boiler area clean and free of fire hazards.
Probe and float type low water cutoff devices require annual inspection and maintenance.
Refer to instructions on Page 51, Item C for inspection and cleaning instructions.
NOTICE
All Series 24 cast iron boilers are designed, built, marked and tested in accordance with the
ASME Boiler and Pressure Vessel Code, Section IV, Heating Boilers. An ASME Data Label is
factory applied to each Series 24 jacket, which indicates the boiler Maximum Allowable Working
Pressure (MAWP). Each cast iron section is permanently marked with the MAWP listed on the
boiler's ASME Data Label. Those values for the Series 24 are as follows:
MAWP, Steam - 15 psi
MAWP, Water (USA) - 80 psi
MAWP, Water (Canada) - 45 psi
It is common and acceptable practice to install these boilers in lower pressure systems, below
the boiler MAWP. Therefore, Crown offers safety relief valves set at or below the MAWP of the
boiler. See page 9 for standard safety relief valve set pressures.
TABLE OF CONTENTS
SECTION I - GENERAL INFORMATION
Dimensional Information ............................................................................................................................................... 8
Ratings/Data .................................................................................................................................................................. 9
Locating the Unit ......................................................................................................................................................... 10
Air Supply/Venting....................................................................................................................................................... 11
SECTION II - CAST IRON BLOCK ASSEMBLY
Assembly of Sections, Manual Draw-up ..................................................................................................................... 13
Assembly of Sections, Hydraulic Draw-up ................................................................................................................. 16
Hydrostatic Test ........................................................................................................................................................... 18
SECTION III - INSTALLATION INSTRUCTIONS
Knockdown
Canopy ......................................................................................................................................................................... 19
Flue Cover Plates ......................................................................................................................................................... 22
Rear Observation Port Cover........................................................................................................................................ 23
Inspect All Boiler Seals ................................................................................................................................................ 23
Jacket Assembly .......................................................................................................................................................... 23
Burner Mounting Plate / Burner Adapter Plate ........................................................................................................... 25
Steam Trim .................................................................................................................................................................. 26
Water Trim . .................................................................................................................................................................. 30
Burner Installation ....................................................................................................................................................... 32
Common Installation Requirements
Boiler Piping - Heating Applications .......................................................................................................................... 32
Boiler Piping - Domestic Hot Water (DHW) Applications .......................................................................................... 33
Tankless Heater Piping ................................................................................................................................................ 41
Electric Wiring.............................................................................................................................................................. 43
Return Temperature Control (RTC) and Components.................................................................................................. 43
SECTION IV - OPERATING INSTRUCTIONS
Filling System............................................................................................................................................................... 47
Adjusting Controls ....................................................................................................................................................... 47
Adjusting Burner ......................................................................................................................................................... 48
Return Temperature Control; Initial Set-Up and Operation ......................................................................................... 48
Diverting Valve Actuator.............................................................................................................................................. 50
Boiler Operating Aquastat ............................................................................................................................................ 50
Boiler High Limit Aquastat .......................................................................................................................................... 50
Boiler Modulating Control ........................................................................................................................................... 50
Test Controls ................................................................................................................................................................ 50
Initial Cleaning, Steam Boilers .................................................................................................................................... 51
Initial Cleaning, Water Boilers .................................................................................................................................... 52
Frequent Water Addition .............................................................................................................................................. 53
Oxygen Corrosion ........................................................................................................................................................ 53
SECTION V - SERVICE INSTRUCTIONS
Cleaning Boiler Heating Surfaces ............................................................................................................................... 54
Maintenance of Low Water Cutoff Devices ................................................................................................................ 55
Checking Burner & Controls........................................................................................................................................ 56
Lubrication ................................................................................................................................................................... 56
General Maintenance Considerations........................................................................................................................... 56
Attention to Boiler While Not in Operation................................................................................................................. 56
6
TABLE OF CONTENTS - Continued
SECTION VI - BURNER SPECIFICATIONS
Beckett Burners (Table VI)........................................................................................................................................... 57
SECTION VII - REPAIR PARTS & CARTON CONTENTS
Regional Office Directory ............................................................................................................................................ 58
Jacket Assembly .......................................................................................................................................................... 60
Bare Boiler Assembly................................................................................................................................................... 62
Steam/Water Trim......................................................................................................................................................... 65
RTC Related Components ............................................................................................................................................ 66
SECTION VIII - APPENDIX
A. Application Drawings - Mechanical and Electrical
A1. 3-way RTC in Primary/Secondary – Heating Only/No DHW; with/without Outdoor reset
A2. 3-way RTC in Primary/Secondary – Heating/DHW with/without priority using Tankless coils and Outdoor reset.
A3. 3-way RTC in Primary/Secondary – Heating/DHW with/without priority using Indirect Water Heater and
Outdoor reset.
A4. 3-way RTC in Primary/Secondary –Indirect Water Heater as load on primary loop without Outdoor reset.
A5. 3-way Multiple Boiler RTC in Primary/Secondary – Indirect Water Heater (or other heat exchanger) as Load on
Primary Loop using Sequencer and Outdoor Reset.
A6. Tankless Application Only with boiler circulation loop. No building heating load.
A7. Indirect Water Heater Only with boiler circulation loop. No building heating load.
B. Boiler Circulator and Diverting Valve Selection Charts
B1. S24, 20 and 40 ∆Τ − Taco
B2. S24, 20 and 40 ∆Τ − Grundfos
B3. S24, 20 and 40 ∆Τ − Bell and Gossett
B4. S24, 20 and 40 ∆Τ - Armstrong
C. Valve and Actuator Mounting Instructions
7
8
TABLE I
BOILER RATINGS/DATA
(1)
(2)
(3)
(4)
Heating
Surface
(Sq. Ft.)
Water
Content
(Gal.)
Boiler Weight
w/ Water
(Lbs.)
Burner
Input
Net
Firebox
Volume Firebox
(Cu.Ft.) ("W.C.)
Pressure
in
Net I=B=R Rating
Gross
Output
(MBH)
Vent
Dia.
(In.)
Boiler Horse-
Model Power
Sq. Ft. MBH MBH
Oil
Gas
Steam Water
Steam Water Steam Water
Steam Steam Water (GPH) (MBH)
24-03
24-04
24-05
24-06
24-07
24-08
24-09
24-10
24-11
24-12
10.2
14.1
18.9
23.8
28.0
32.5
39.3
45.0
50.5
55.3
342
471
1071
1471
1983
2492
2929
3396
4146
4788
5429
5983
257
353
476
598
703
815
995
297
410
3.05 438
34.2
48.6
63.0
77.5
37.0
54.3
71.5
88.8
3.2
4.8
.33
.38
.31
.38
.36
.35
.35
.40
.45
.49
44.5
53.0
61.5
70.0
66.0
75.0
84.0
93.0
1439 1618
1811 1995
2184 2372
2557 2749
7
7
4.10
594
792
990
634
551 5.50
6.4
8
797
693
815
945
6.90
7.9
8
937
8.10 1174
91.9 106.0
9.5
78.5 102.0 2930 3126
8
1087
1316
1505
1690
1852
9.40 1358 106.3 123.3
11.0
12.6
14.2
15.7
17.3
87.0
111.0 3303 3503
10
10
10
12
12
1148 11.40 1641 120.7 140.5
95.5 120.0 3676 3880
104.0 129.0 4048 4257
112.5 138.0 4421 4634
1149 1309 13.00 1867 135.1 157.8
1303 1470 14.60 2093 149.5 175.0
1436 1610 16.00 2320 164.0 192.3
121.0 147.0 4794
5011
(1) Trim Suffix: S = Steam Boiler, W = Water Boiler
Fuel Suffix: N = Natural Gas, P = LP Gas, O = Oil
(2) I=B=R net ratings shown are based on piping and pick-up allowances which vary from 1.333 to 1.289 for steam and
1.15 for water. Consult manufacturer for installations having unusual piping and pick-up requirements, such as
intermittent system operation, extensive piping systems, etc. The I=B=R burner capacity in GPH is based on oil having a
heat value of 140,000 BTU per gallon.
(3) Firebox volume does not include added volume of 8” extended burner mounting plate (BMP). If 8” BMP is specified
(refer to Figure 1), add 0.7 cu. ft. to volume listed above.
(4) Boiler ratings are based on 12.5% CO2 (oil) and 9.7% CO2 (natural gas), + .10” (inches) water column pressure at boiler
flue outlet. Ratings shown above apply at altitudes up to 1000 feet on oil and 2000 feet on gas.
For altitudes above those indicated, the ratings should be reduced at the rate of 4% for each 1000 feet above sea level.
Maximum Allowable Working Pressure: Steam Boiler - 15 PSI, Water Boiler - 50 PSI
Standard Safety (Relief) Valve Set Pressure: Steam Boiler - 15 PSI, Water Boiler - 30 PSI
9
SECTION I - GENERAL INFORMATION (CONTINUED)
the boiler jacket of 12”.
A. INSPECT SHIPMENT carefully for any signs of
TOP — Provide a minimum clearance from the
boiler jacket of 24”
damage.
1. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of crated boiler to the carrier in good
condition.
2. FOR MINIMUM CLEARANCES to combustible
materials, See Table II.
3. PROVIDE ADEQUATE FOUNDATION for the
unit. Refer to Figure 2.
2. ANY CLAIMS for damage or shortage in shipment
must be filed immediately against the carrier by the
consignee. No claims for variances from, or short-
age in orders, will be allowed by the manufacturer
unless presented within sixty (60) days after the
receipt of goods.
Table II: Minimum Clearances To Combustible
Materials (Inches)
3. Make sure that appropriate items on the Master Parts
List (pg 59) are all on hand.
B. LOCATE THE UNIT
1. RECOMMENDED SERVICE CLEARANCE
- Locate the unit in the boiler room so as to
provide ease of venting and adequate clearance
for maintenance, serviceability, and installation of
piping. Refer to Figure 1 for boiler dimensional
data.
Boilers with Top Flue Outlet
FRONT — Provide 43” service clearance for
removal, maintenance, and servicing of burner and
controls.
REAR — Provide a minimum clearance from the
boiler jacket for access to flame observation port,
rear flue damper and vent piping, relief valve, and
boiler return piping. See Table III.
Boilers with Rear Flue Outlet
LEFT SIDE — Provide a minimum clearance from
the boiler jacket of 26” for cleaning of flueways and
installation and removal of tankless heater(s).
A
B
Front
C
Rear
D
Sides
E
Above
Vent Connector
RIGHT SIDE — Provide a minimum clearance from
6
24
6
6
18
* See Table III for Recommended service clearance to access
rear of boiler
NOTICE
NOTE 1: Listed clearances comply with American National
Standard ANSI/NFPA 31, Installation of oil burning equipment.
Recommended clearance for service may be
reduced to minimum clearance to
combustible material. However, increased
service and maintenance difficulty will
result.
NOTE 2: Series 24 boilers can be installed in rooms with
clearances from combustible material as listed above. Listed
clearances can not be reduced for alcove or closet
installations.
NOTE 3: For reduced clearances to combustible material,
protection must be provided as described in the above
ANSI/NFPA 31 standard.
WARNING
Boiler is suitable for installation on
combustible floor. Do not install boiler
on carpeting.
Table III: Recommended Rear Service Clearance
Rear Flue Outlet
Flue
Outlet
Size
Top
Flue
Outlet
Floor construction should have
adequate load bearing characteristics
to bear the weight of the boiler filled
with water (see Table 1). A boiler
foundation similar to the one shown in
Figure 2 is recommended if the boiler
room floor is weak or uneven or if a
water condition exists.
Combustible
Surfaces
Non-Combustible
Surfaces
7" Dia.
8" Dia.
37"
38"
40"
43"
22"
23"
25"
28"
18"
10" Dia.
12" Dia.
10
Figure 2: Boiler Foundation
b. If horizontal ducts are used, each opening shall
WARNING
have a free area of not less than 1 sq. inch
per 2,000 Btuh (70 sq. inch per gph.) (11 cm2
per kw) of total input of all appliances in the
enclosure.
Failure to supply adequate air to the boiler
will result in unsafe boiler operation.
D. CHIMNEY OR VENT
C. PROVIDE AIR SUPPLY AND VENTILATION to
The Series 24 boiler is designed for forced draft firing
and may be used with a conventional natural draft
stack (15’ minimum height) or a stub vent, sometimes
called a diesel stack (see Figure 3a). See Table I for
the proper vent outlet size. For low silhouette vent
terminations, see Figure 3b. Draft controls are not
normally required, although they may be used on
installations where a natural draft stack is used or on
multiple boiler installations with a common stack. The
boiler is provided with a breeching damper, which
should be adjusted to maintain a positive pressure of
0.1” W.C. in the vent connector box during burner high
fire operation (see breeching pressure sensing port in
Figure 1).
accommodate proper combustion.
For commercial and industrial equipment, permanent
facilities for supplying an ample amount of outside air
shall be provided in accordance with the following.
For boiler rooms adjacent to outside walls, and where
combustion air is provided by natural ventilation from
the outside, there shall be a permanent air supply inlet
having a total free area of not less than 1 sq. inch per
4,000 Btu per hr. (35 sq. inch per gallon per hour)
(5.5 cm2 per kw.) of total input rating of the burner or
burners and in no case less than 35 sq. inch (0.425m2).
For boiler rooms not adjacent to outside walls, the
combustion air shall be supplied in a manner acceptable
to the authority having jurisdiction.
1. In the absence of local requirements, the confined
space shall be provided with two permanent
openings, one in or near the top of the room and one
near the bottom. The openings shall communicate
by means of ducts, with the outdoors or to such
spaces (crawl or attic) that communicate with the
outdoors.
a. Where communicating by means of vertical
ducts, each opening shall have a free area of not
less than 1 sq. inch per 4,000 Btuh (35 sq. inch
per gph) (5.5 cm2 per kw) of total input rating of
all appliances in the enclosure.
Figure 3a: Typical Arrangement for Stub Vent
11
If the venting system is designed for positive or forced
draft venting, the boiler, vent connector and stack will
operate under positive pressure. Gas tight vent systems
designed for pressure systems must be used to prevent
flue by-product leakage. The vent height is usually
limited to prevent negative draft, typically three (3)
feet above the roof line (see Figure 3a). The damper
shall be adjusted to maintain a positive pressure of 0.1”
W.C. in the vent connector box during burner high fire
operation (see breeching pressure sensing port in Figure
1).
If the venting system is designed for negative pressure
(natural draft), the boiler still operates with positive
pressure in the chamber and up to the fixed damper on
the flue collar. However, if the venting system is larger
than what is required, the stack will provide a surplus
draft (or negative pressure) that may require the use of
a barometric damper to maintain the positive 0.1” W.C.
pressure at the flue outlet. Multiple forced draft boiler
stacks should always be designed as negative to ensure
the products of combustion do not exit a boiler that is
not firing.
WARNING
Venting Instructions are recommendations only. Consult a venting expert on the design of
a specific vent system for your application. The ASHRAE Venting Guide and The National
Fuel Gas Code, NFPA 54 should be considered in all venting systems.
Conventional vent material may not be suitable for the application. Flue gases can leak
carbon monoxide from the joints on these materials and can result in severe personal injury
or death.
Installations having long horizontal runs or an excessive amount of tees or elbows will
restrict the flow of combustion gases and can result in condensation, flue gas leakage of
carbon monoxide, resulting in severe personal injury or death.
FIGURE 3b: VENTS — FAULTS & SUGGESTIONS
TYPICAL VENTS THAT ARE USED ON FORCED DRAFT BOILERS, ON LOW SILHOUETTE BUILDINGS
C
A
B
RAIN CAP
RIGHT
“A” CAP
RIGHT
TEE TYPE
RIGHT
E
D
90°
ELBOW
UP or DOWN
WRONG
WRONG
VENT SIZING - Area must be the same as or greater than the boiler breeching (Smoke Outlet). A barometric damper may be required on
installations with a high draft condition.
FAULTY BOILER BURNER OPERATION
1. If improper vent is suspected, remove pipe at breeching and operate boiler. This will determine if excessive down draft,
blocked or restricted flue, etc. is causing the problem.
2. If using type shown in A above, be sure cap is raised sufficiently above main pipe to allow flue gases to vent unimpeded.
3. A popular type cap is shown in B.
4. The tee is frequently used as shown in C.
5. D and E should not be used due to possible fluctuations in back pressure.
12
SECTION II - CAST IRON BLOCK ASSEMBLY
ENSURE THAT THE ADHESIVE DOES
NOT COME IN CONTACT WITH THE
NIPPLES OR NIPPLE PORTS.
CAUTION
Boiler sections must be drawn-up on
perfectly level surface or improper
assembly may result.
e. Clean nipples and nipple ports thoroughly with
a de-greasing solvent. Use the Loctite #592
supplied to lubricate the nipples and nipple
ports. Apply the lubricant to the nipples and
nipple ports, then use a brush to disperse it
evenly around the nipples and the nipple ports.
Use approximately 25 ml of Loctite #592 per
flueway [(1) 7” and (2) 3” nipples and their (6)
corresponding nipple ports].
A. FIELD ASSEMBLED SECTIONS — If the boiler
was ordered to be field assembled, follow the assembly
procedure outlined on the following pages.
1. ASSEMBLY OF SECTIONS (MANUAL DRAW-
UP)
These sections are designed to be drawn together,
one section at a time, using the 9¾” long draw-up
rods (provided) and ordinary hand tools.
f. Drive nipples squarely into section using
block of wood and hammer, or preferably,
an aluminum head hammer. (Crown offers a
Polyethylene Block for setting the nipples, part
number 330010). Place block over entire nipple
edge and hit the wood with the hammer.
Tools required:
(1) ¾” Drive Ratchet
(1) 1-1/16” Socket
(1) 1-1/16” Combination or Open End Wrench
(1) Container of grease, oil or other appropriate
lubricant.
CAUTION
When assembling sections without
hydraulic draw-up equipment, never
assemble more than one section at a time.
a. Place the rear section in its approximate final
position, as outlined in Section I, and support it
with a suitable prop and wedges. See Figure 5.
b. On size 24-03 only— Open target wall carton,
apply Silastic to back of target wall and secure
target wall to rear section.
c. Clean the groove in the ground joint along the
edge of the section with the wire brush.
d. Open the Boiler Assembly Carton(s) and remove
the bottle of adhesive. Using the dauber supplied
in the bottle, apply the adhesive to the groove.
Be sure to use enough adhesive to sufficiently
coat the entire groove surface. If so desired,
a multi-purpose spray adhesive (supplied by
others) may be used instead. HOWEVER,
GREAT CARE MUST BE TAKEN TO
Figure 5: Positioning of Back Section
13
WARNING
Nipples must be driven in evenly and to
the proper depth to assure tight joints.
Most nipple leaks are caused by tilted
or cocked nipples.
DO NOT use steel/iron head hammer to
drive nipples without using a wood
block. Nipple damage may result.
g. A special nipple setting gauge is provided for
the nipples. Gauge nipple in both directions to
insure that it is driven to the proper depth into
the nipple opening (nipple port). Cut-out in
gauge must rest on nipple, with legs of gauge
touching finished face of section, when nipple is
properly driven. See Figure 6.
h. Remove a 96” length of fiberglass rope from the
assembly carton. Starting with the area around
the upper 7” nipple port, firmly press the rope
into the groove, so that the adhesive holds it in
place. (If more than 25 minutes have passed
since the adhesive was applied, it may be
necessary to reapply.) Continue to affix the
rope to the groove in this fashion around the
perimeter of the section. Make sure that the rope
does not droop or hang outside of the groove.
When the end of the groove is reached, cut off
the excess rope. Push the length of excess rope
into the groove at the top corner of the section
face (opposite of the 7” nipple port.) Cut off and
discard any remaining rope after groove is filled.
See Figure 7.
Figure 6: Nipple Gauge
WARNING
Sections must be drawn-up tight
immediately after properly applying
sealant for best results. Although
sections may be joined within two (2)
hours of applying sealant, humidity and
temperature affect cure time. If a "thick
skin" has been formed on the sealant
bead, remove and re-apply sealant.
Sealant must be properly applied to
ALL grooves. Failure to properly seal
the boiler joints will result in
combustion gas leaks through the joint.
DO NOT operate boiler with
combustion gas leaks.
Figure 7: Affixing the Fiberglass Rope
14
BOILER SECTION IDENTIFICATION CODE
F = FRONT SECTION WITH 4” SUPPLY TAPPING
B = BACK SECTION WITH 4” SUPPLY TAPPING
C = CENTER SECTION
CX = CENTER SECTION WITH 4” TOP SUPPLY TAPPING
NOTES: FOR BOILERS LESS TANKLESS HEATER, REPLACE THE “CT” SECTIONS WITH “C” SECTIONS.
Figure 8: Series 24 Section Arrangement
i. From the “Section Arrangement” chart, select
the next section according to the “Identification
Code” at the top of the chart. See Figure 8. Use
a wire brush to clean the groove in the face of
(crowbar) under the center of the section and lift
the nipple port onto the upper nipple.
k. Drive section in place with a heavy block of
wood, striking blows as squarely as possible over
nipple port.
NOTICE
l. The large draw-up rod lugs with dual holes
are cast in the four (4) corners of each casting.
Starting with the upper holes, install four
(4) 5/8” x 9¾” long draw-up rods along with
washers and nuts (see Figure 9).
The sections must be assembled according
to the arrangement shown to ensure proper
operation, proper assembly of canopy,
jacket and alignment of piping and tankless
heaters with jacket knockouts. Start with
the back section and work towards the
front.
CAUTION
To avoid damage to the draw-up rod
threads while drawing up sections, apply
oil or other lubricant to tie rod threads
while assembling sections to prevent
stripping of threads on rod and to make
assembling easier.
the next section. Then, using a cartridge of RTV
6500 or RTV 736 sealant in a caulking gun, fill
the groove in this section with silastic sealant.
Touch-up any missed spots before draw-up.
Touch-up after draw-up has no value.
j. Clean and lubricate nipple ports on next section
to be assembled and place on nipples previously
installed in rear section. To facilitate assembly,
it is advisable to enter the upper nipple first in
its port. Then enter the lower nipples in their
respective ports. If necessary, place a lifting bar
m. DRAW UP SECTION SLOWLY AND
EVENLY using an alternating pattern starting
with the upper right lug and proceeding to the
lower left , lower right and finishing with upper
left lug.
15
excessive, periodically place a heavy block of
wood over each nipple port and strike as squarely
as possible with several blows to relieve tension
on the draw-up rods.
n. CONTINUE ASSEMBLING SECTIONS IN
THEIR RESPECTIVE ORDER alternating
the draw-up rods from the upper to lower set
of holes in draw-up lugs. Be certain that all
sections are drawn up IRON-TO-IRON at all
three (3) nipple ports.
BE SURE TO APPLY THE SEALANT to
the groove in the ground joints between
adjacent sections as the boiler operates with a
positive pressure in the firebox and products of
combustion will escape between sections unless
the sections are properly sealed. The sealant
should be applied before each section is placed
on the assembly.
o. If a joint springs apart it must be redrawn tight
within four (4) hours of the time of application of
Silastic to that joint.
Figure 9: Draw-Up Rods (Alternating Pattern -
Manual Draw-up)
2. ASSEMBLY OF SECTIONS (HYDRAULIC DRAW-
UP)
When you start, grind surfaces between
adjoining sections should be approximately
3/8” apart. Use three (3) or four (4) passes at
tightening the four (4) draw-up rods a little at
a time so that sections are pulled up evenly.
During the last pass, pay close attention to the
silastic sealant as it squeezes when the sections
come in close contact. The silastic sealant will
continue to squeeze out wafer thin until the
sections are connected metal to metal. While
tightening the nuts, close attention should be
given to the connection area to determine that
the silastic has stopped squeezing out from
between the sections. This will give assurance
that the sections are assembled metal to metal. If
the silastic has stopped squeezing out from the
connection and the sections still do not appear
to be drawn metal to metal, measure any gaps
between the sections with a feeler gauge. A
maximum gap of .025” is acceptable. Gaps
should be measured at the outer edge of the
connection. DO NOT PUNCTURE THE
GASKET CREATED BY THE FIBERGLASS
ROPE AND SILASTIC
The entire boiler assembly may be drawn up at one
time using hydraulic draw-up equipment providing
the operation is completed within four (4) hours after
application of the sealant.
a. Repeat steps 1a through 1k under “Field
Assembled Sections (Manual Draw-Up).”
b. Continue driving sections in place (in their
respective order) until all sections are in the
assembly. Ground surfaces between adjoining
sections should be spaced 1/4” to 3/8” apart.
Spacing of more than 3/8” will limit number of
sections that can be drawn up in one unit and
could indicate cocked nipples.
WARNING
Sealant must be properly applied to ALL
grooves. Failure to properly seal the boiler
joints will result in combustion gas leaks
through to joint. DO NOT operate boiler
with combustion gas leaks. The sealant
should be applied before each section is
placed on the assembly.
SEALANT WITH THE FEELER GAUGE.
On long boiler assemblies, it may be necessary to
draw-up a partial block if the entire boiler is not
ready to be drawn-up tight within four (4) hours
of the first application of Silastic. If the block
assembly time extends overnight, the partial block
completed must be drawn-up tight before leaving
the boiler overnight. If a joint springs out, it must
be redrawn tight within four (4) hours of first
application of Silastic to the joint.
WARNING
Do not over torque draw up nuts after grind
surfaces meet.
KEEP NIPPLES ALIGNED WITH NIPPLE
PORTS. If necessary, tap edge of nipples lightly
with a blunt tool or rod to keep nipples from
cocking while sections are being drawn-up. DO
NOT DRAW UP SECTION WHEN NIPPLES
ARE COCKED. If the torque required becomes
c. Insert the three (3) ¾” draw-up rods (and
couplings, if appropriate) through the tapped holes
in the rear section extending them through the
16
tapped holes in the front section. Be sure to
screw draw-up rods into couplings far enough to
prevent stripping threads.
g. After all sections have been drawn up, but before
removing the hydraulic rams and draw-up rods,
the 9¾” long tie rods must be installed.
d. Place a 3” x 12” lg. steel channel on each end of
the upper draw-up rod and a 3” x 8½” lg. steel
channel on each end of the lower draw-up rods.
The large draw-up rod lugs with dual holes
are cast in the four (4) corners of each casting.
Starting with the upper holes in the back section,
install four (4) 5/8” x 9¾” long tie rods along
with washers and nuts. Continue installing the
tie rods alternating from the upper to lower set
of holes in draw-up lugs until front section is
secured. Be certain that all sections are drawn
up IRON TO IRON at all three nipple ports.
Refer to Figures 10 and 11 for proper placement
of channel block during assembly procedures.
Install nuts and washers on one end of the draw-
up rods and the hydraulic rams, washers and
draw-up rod clamps on the other. See Figure 13.
h. Excess length of draw-up rods must not extend
beyond front and rear section. To ensure proper
fit of jacket, adjust accordingly. Tighten all tie
rod nuts until finger tight. Then tighten them
an additional ½ turn with a wrench to prevent
section damage to thermal expansion.
CAUTION
Do not apply pressure directly on threaded
tappings on front and rear sections with
draw-up channels during assembly
procedures.
Rods should be approximately centered in
openings so that rods and couplings (when
used) do not drag on pipe thread in end
section tappings.
WARNING
READ THE STATEMENTS BELOW BEFORE
ATTEMPTING TO USE HYDRAULIC EQUIPMENT.
Figure 10: Front and Rear Section Channel
Block Positions (Hydraulic Draw-up)
* Release pressure in ram pumps before
attempting to remove clamps.
* Do not stand in line with draw-up rods at
either end when hydraulic pressure is
being applied. As a safety measure,
ends of draw-up rods should be covered
while sections are being drawn in case
rods should snap while under tension.
* Do not operate ram against draw-up
coupling.
* Do not operate pump after ram has
reached stroke limit.
e. Draw-Up Sections
Use hydraulic rams to draw up sections by
applying pressure alternately on the draw-up
rods. When rams reach stroke limit, release
pressure in ram pumps and then move clamps to
new position.
f. Continue to draw-up until all sections make
contact at the ground joints.
Figure 11: Center Section Channel Block Position
(Partial Block Draw-Up)
17
Figure 12: Hydraulic Draw-Up of Sections
B. HYDROSTATIC TEST — After the boiler sections
4. EXAMINE BOILER CAREFULLY, INSIDE AND
OUTSIDE, to insure against leaks from cocked
nipples or through concealed breakage caused in
shipping and handling. This precaution is for your
protection and will simplify handling of necessary
replacements and adjustment claims.
have been assembled, it is essential that the boiler be
hydrostatically tested before the canopy, flue cover
plates, jacket, or piping is installed.
1. Tankless Heater Installation
If boiler is ordered with tankless heaters, install
heaters with the gaskets provided. Table IV
on Page 37 gives the maximum number of heaters
permissible per assembly and the heater ratings.
5. After making certain that there are no leaks, drain
boiler and remove plugs for boiler trim and other
connections.
2. Plug all boiler tappings and fill boiler completely
with cold water.
CAUTION
DO NOT install gauge until after hydrostatic
testing the boiler. Gauge failure may result.
3. All completed boilers must satisfactorily pass the
prescribed hydrostatic test.
a. STEAM BOILERS: The assembled boiler must
be subjected to a hydrostatic test of 45 psig to 55
psig.
b. HOT WATER BOILERS: The assembled boiler
must be subjected to a hydrostatic test of not less
than 1½ times the maximum allowable working
pressure (MAWP).
WARNING
Failure to properly hydrotest all boilers at
the correct pressure may result in section
assembly failure in operation.
Figure 13: Boiler Section Assembly
18
SECTION III - INSTALLATION INSTRUCTIONS
A. INSTALL CANOPY/FLUE OUTLET ASSEMBLY,
Refer to Figures 14, 15 and 16.
1. Open canopy carton.
2. Attach the two (2) canopy brackets to the front end
cap of canopy with four (4) #10 x 1/2” sheet metal
screws each.
3. Across the top of the front section and along the top
ledges running back each side of the sections, place
continuous 2” wide strips of cerafelt and overlap
joints at front corners. Cerafelt strip should extend
1/4” beyond rear surface of back section. Cut off
excess.
4. Place the canopy on the sections.
5. Position rear flange (end with studs) of canopy flush
with rear surface of back section.
6. Loosely attach the canopy brackets to the lugs on
the front section of the block assembly with 5/16”
carriage bolts, flat washers and locknuts.
7. Check to see if rear flange of canopy is still flush
with raised flange on back section.
8. Open either the rear flue outlet carton (standard) or
top flue outlet carton (optional).
9. Attach the 1/8” x 1” wide self-adhesive fiber gasket
to the surface of either the rear flue outlet damper
assembly or rear flue outlet cover that mounts
against the canopy and back section. Gasket must
be centered over all attachment holes. Do not
overlap corners, cut butt joints.
Figure 14: Canopy with Rear Flue Outlet
Damper Assembly
10.Attach either the rear flue outlet damper assembly
or rear outlet canopy cover to the canopy with the
5/16” flat washers, lock-washers and brass
nuts and tighten securely. Attach the rear flue
outlet damper assembly or cover to the back section
with the four (4) 5/16” flat washers and cap screws
and tighten securely.
11.Tighten front canopy carriage bolt until canopy is
secure.
12.On the longer canopy sizes, Intermediate Mounting
Brackets are provided, two (2) are required on sizes
24-07 thru 24-09 and four (4) are required on sizes
24-10 thru 24-12A. Refer to Figures 17 and 18.
a. Intermediate brackets are shipped flat. Bend
side flanges down approximately 90° as shown.
Adjust bends until holes in bracket match hole
pattern on canopy.
b. Secure brackets to both sides of canopy with
three (3) #10 x ½” sheet metal screws per
bracket.
c. Secure canopy left side bracket(s) with
appropriate canopy ‘J’ bolt(s). Insert threaded
end through holes in brackets and hook ‘J’ bolt
on center section draw-up rod (hooks should
Figure 15: Canopy with Top Flue Outlet
Damper Assembly (Rear Cover Removed)
19
20
Important Product Safety Information
Refractory Ceramic Fiber Product
Warning:
This product contains refractory ceramic fibers (RCF). RCF has been classified
as a possible human carcinogen. After this product is fired, RCF may, when
exposed to extremely high temperature (>1800F), change into a known human
carcinogen. When disturbed as a result of servicing or repair, RCF becomes
airborne and, if inhaled, may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace previously fired RCF (combustion chamber insulation,
target walls, canopy gasket, flue cover gasket, etc.) or attempt any service or
repair work involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH) ap-
proved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
• Take steps to assure adequate ventilation.
• Wash all exposed body areas gently with soap and water after contact.
• Wash work clothes separately from other laundry and rinse washing ma-
chine after use to avoid contaminating other clothes.
• Discard used RCF components by sealing in an air tight plastic bag.
First Aid Procedures:
• If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
• If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
• If breathing difficulty develops: Leave the area and move to a loca-
tion with clean fresh air. Seek immediate medical attention if breath-
ing difficulties persist.
• Ingestion: Do not induce vomiting. Drink plenty of water. Seek im-
mediate medical attention.
21
Figure 17: Left Side Canopy Intermediate Bracket
Figure 18: Right Side Canopy Intermediate Bracket
face outward). Secure canopy with 5/16” flat
washers, lock washers and brass nuts. See
Figure 17.
against boiler and secure with washers and nuts.
Tighten until insulation on cover plate provides a
tight seal to casting. If after tightening, a gap is still
evident where the sections join, apply silastic along
top and bottom edge of insulation board.
d. Secure canopy right side bracket(s) with ¼ - 20
x 5” lg. carriage bolts. Insert head of carriage
bolt between canopy body and casting. Slide
carriage bolt into slot provided between castings.
Lower carriage bolt until threaded end will pass
through hole in bracket. Secure canopy with ¼”
flat washers, lock washers and brass nuts. See
Figure 18.
5. Repeat steps 3 through 6 for mounting remaining
flue cover plates.
13.Attach the 1/8” x 1” wide self-adhesive fiber gasket
to the surfaces of either the top flue outlet damper
assembly or top outlet canopy cover that mounts
against the canopy. Gasket must be centered over
all attachment holes. Do not overlap corners, cut
butt joints.
14.Secure either the top flue outlet damper assembly or
top outlet canopy cover with #10 x 1/2” sheet metal
screws.
B. INSTALL FLUE COVER PLATES over cleanout
openings on left side of boiler as shown in Figure 19.
See Important Product Safety Information on Page
21 of this manual, regarding refractory ceramic
fiber product warning.
1. Locate the cover plates, carriage bolts, nuts and
washers in the boiler assembly carton(s).
2. Remove insulation from two (2) 3/8” diameter holes
in flue cover plates using a 3/8” drill bit. Rotate bit
through insulation by hand.
3. Attach the carriage bolts to the top and bottom of the
flue openings with washers and hex nuts to provide
a fixed stud.
Figure 19: Flue Cover Plate Attachment
4. Install flue cover plates over studs with insulation
22
6. Jacket Top Panel Attachment
C. MOUNT REAR OBSERVATION PORT COVER
Refer to Figure 16.
a. On boilers with top flue outlet damper assembly,
remove octagon shaped knockout. To remove
knockout, use a single hacksaw blade with handle
or aviation snips to cut metal tabs between
slotted holes.
1. With the silastic sealant, secure the 3/16” diameter
rope gasket into the groove around the perimeter of
the rear observation port cover.
2. Mount the rear observation port cover onto the rear
section (with the word “Top” in the upright position)
using the four (4) 5/16” - 18 x 1” lg. cap screws and
flat washers provided.
b. Remove knockout(s) for necessary supply piping
in a similar manner.
c. Attach jacket top panel to the front panel, rear
panel and upper tie bar panels with sheet metal
screws.
D. INSPECT ALL BOILER SEALS
1. A visual inspection should be made of all sealed
joints and repairs made as necessary. Darken
the boiler room and place a light source in the
combustion space and canopy to observe any gaps
or open seals. Poor seals must be repaired and
rechecked before continuing.
7. Install Jacket side Panels
a. Snap black thumb hole bushings into all side
panel holes.
b. Use the left side panel and right side panel usage
charts to determine correct positions of side
panels. The three (3) digit panel identification
numbers shown in the charts are also stamped
along the bottom edge of each panel. Refer to
Figures 20 and 21.
E. JACKET ASSEMBLY - See Figure 22 for Jacket
Assembly Details.
1. Open jacket carton and jacket hardware package.
Unless otherwise stated, all jacket components are
fastened with #8 x ½” hex head sheet metal screws.
Do not drive sheet metal screws tight until jacket
assembly is complete.
c. Rearward and Intermediate panels have reverse
bend flanges on one side of panel. These panels
must be installed prior to forward panels.
NOTICE
2. On boilers with rear flue outlet damper assembly,
remove square knockout from jacket rear panel. To
remove knockout, use a single hacksaw blade with
handle or aviation snips to cut metal tabs between
slotted holes.
To install multiple side panels, start at the
rear of boiler and work forward. To remove
panels, reverse order of assembly.
d. If boiler is equipped with tankless heaters they
should be installed at this time if they were not
installed for hydrostatic test outlined on Page 18.
3. Attach jacket front panel to front section and jacket
rear panel to back section using the eight (8) #10
x ½” self tapping screws. Tighten these screws
securely.
e. Install right side panels into position by inserting
top of panel into ‘U’ shaped channel, pushing
bottom of panel in toward boiler, and sliding
panel down into ‘J’ shaped channel. Repeat
procedure until all right side panels are in place.
4. Attach jacket lower tie bar panel (approximately
5-5/8” high) to the bottom of the jacket front and
rear panels using four (4) sheet metal screws.
Repeat for opposite side.
f. Remove the knockouts necessary for tankless
heater operation on left side panels.
5. Attach jacket upper tie bar panel (approximately
4-1/8” high) to the top of the jacket front and rear
panels using four (4) sheet metal screws. Repeat for
opposite side.
g. Install left side panels, using the same procedure
used to install the right side panels.
JACKET LEFT SIDE PANEL USAGE CHART
RIGHT SIDE PANEL USAGE CHART
MULTIPLE LEFT SIDE PANELS*
SINGLE / MULTIPLE RIGHT SIDE PANELS*
BOILER
MODEL
BOILER
MODEL
PANEL 1
L10
PANEL 2
L5
PANEL 3
PANEL 4
PANEL 5
PANEL 3
PANEL 2
PANEL 1
R15 (SINGLE)
R21 (SINGLE)
R27 (SINGLE)
R33 (SINGLE)
R24
24-03
24-04
24-05
24-06
24-07
24-08
24-09
24-10
24-11
24-12
-
-
-
-
24-03
24-04
24-05
24-06
24-07
24-08
24-09
24-10
24-11
24-12
-
-
L10
L11
-
-
-
-
-
L10
L17
-
-
-
-
L10
L18
L5
-
-
-
-
L10
L18
L11
L17
L18
L18
L18
L18
-
-
-
R15
R21
R27
R27
R33
R24
L10
L18
-
-
-
R24
L10
L18
L5
L11
L17
L18
-
-
R24
L10
L18
-
-
-
R30
L10
L18
-
R30
L10
L18
L5
R21
R24
*NOTE: TO INSTALL MULTIPLE SIDE PANELS, START AT THE REAR AND WORK FORWARD. TO REMOVE PANELS, REVERSE ORDER OF ASSEMBLY.
Figure 21: Right Side Panel Usage Chart
Figure 20: Left Side Panel Usage Chart
23
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