CleaverBrooks FLE, Assembly Instructions Manual

Page 1: ...Model FLE Assembly Instructions 750 192 07 09 Field Erectable Flexible Watertube Boiler ...

Page 2: ...ecified on the boiler name plate DANGER WARNING Should overheating occur or the gas sup ply valve fail to shut off do not turn off or disconnect the electrical supply to the boiler Instead turn off the gas supply at a location external to the boiler DANGER WARNING Do not use this boiler if any part has been under water Immediately call your Cleav er Brooks service representative to in spect the bo...

Page 3: ...ements to UL 795 Commercial In dustrial Gas Heating Equipment and or the National Fuel Gas Code ANSI Z223 1 DANGER WARNING The boiler and its individual shutoff valve must be disconnected from the gas sup ply piping system during any pressure testing of that system at test pressures in excess of 1 2 psi 3 5 kPa DANGER WARNING ...

Page 4: ...iv Notes ...

Page 5: ...for replacement manuals to your local Cleaver Brooks authorized representative Manual Part No 750 192 07 09 Printed in U S A Cleaver Brooks 2009 CLEAVER BROOKS Model FLE Field Erectable Flexible Watertube Boiler Assembly Instructions ...

Page 6: ...how how a basic burner operates Operating controls will normally function for long periods of time and we have found that some operators become lax in their daily or monthly testing assuming that normal operation will continue indefinitely Malfunctions of controls lead to uneconomical operation and damage and in most cases these conditions can be traced directly to carelessness and deficiencies in...

Page 7: ... FLE Casing Assembly Procedures 1 Install Wetpack around Vent Tube 3 8 2 Install Backing Plates 3 8 3 Install Rear Wall Sections 3 9 4 Drill Rear Sight Port 3 12 5 Wetpack Installation Around Lower Drum 3 14 6 Finish Installing Backing Plates 3 14 7 Install Front Wall Section 3 14 8 Install Roof Panel 3 14 9 Install Burner Door 3 16 10 Install Lift Lug Cover 3 17 11 Install Drum Packing and Seal P...

Page 8: ...viii ...

Page 9: ...ernal 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...

Page 10: ...79 315 1281 315 1282 315 1282 Corner Piece APPROX SIZE in 23x16 1 2 20x19 26x20 27x23 27x23 Insulated WEIGHT lbs 30 35 40 45 45 Roof Assembly PART NO 315 1127 315 1167 315 1178 315 1192 315 1202 Insulated APPROX SIZE in 75x42 74x38 95x39 118x45 140x45 WEIGHT lbs 185 215 280 370 430 Upper Drum PART NO 270 2703 270 2704 270 2705 270 2706 270 2707 Assembly APPROX SIZE in 14x54 1 4 16x60 1 4 17x81 1 4...

Page 11: ...1230 315 1239 315 1250 315 1260 315 1215 315 1230 315 1239 315 1250 315 1260 Insulated APPROX SIZE in 68x34 74x37 95x40 116x45 140x45 68x34 74x37 95x40 116x45 140x45 WEIGHT lbs 185 215 280 370 430 185 215 280 370 430 Upper Drum PART NO 270 1527 270 1528 270 1529 270 1530 270 2510 270 1523 270 1524 270 1525 270 1526 270 2582 Assembly APPROX SIZE in 20x98 20x104 20x126 24x150 24x182 20x98 20x104 20x...

Page 12: ...mic 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 Fibrefax white insulation supplied in tubes 4 Pressure Vessel Assembly Assembly of the pressure vessel will require the following components also refer to the packing list Top and bottom drums Fanged bolts and gaskets Boiler tubes Ba...

Page 13: ...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...

Page 14: ...FLE Assembly 1 6 750 192 1 HIGH LIMIT PRESSURE CONTROL 2 OPERATING LIMIT PRESSURE CONTROL 3 MODULATION PRESSURE CONTROL 4 PRESSURE GAUGE 5 WATER COLUMN Figure 1 6 Typical Gas Train Figure 1 7 Trim Components Hot Water 1 2 3 4 5 ...

Page 15: ... firing controls Low water cutoff Conduit and wire Pipe components Standard electrical tools conduit bender wire puller etc Wiring diagram NOTE When the burner is being in stalled a means of safely lifting the burner will be required Refer to the Op eration and Maintenance manual for burner weights Additional parts included in the assembly kit include standoffs These are welded to the drum front o...

Page 16: ...General Description Model FLE Assembly 1 8 750 192 ...

Page 17: ... 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 ligh...

Page 18: ... to End Steam Hot Water Steam Hot Water 150 60 56 1 2 98 98 3 8 200 60 56 1 2 98 98 3 8 250 60 56 1 2 98 98 3 8 300 64 60 1 2 104 104 3 8 350 64 60 1 2 104 104 3 8 400 67 63 1 2 126 126 3 8 450 67 63 1 2 126 126 3 8 500 67 63 1 2 126 126 3 8 550 67 63 1 2 126 126 3 8 600 67 63 1 2 126 126 3 8 700 77 69 1 2 150 147 800 77 69 1 2 150 147 900 77 69 1 2 150 147 1000 77 69 1 2 182 172 1 2 1100 77 69 1 ...

Page 19: ...wed by the side sections 4 Positioning the Lower Drum on the Base Cut the base strip into three equal pieces Layer them on the base between the refractory and drum support The 5 wide strip is for the front and the 7 for the rear Position the lower drum on the base and place one bolt on both the front and the rear Once this is finished secure the four bolts on the rear then the four bolts on the fr...

Page 20: ... drum spreaders are shown in Table 2 2 See table 2 1 for drum dimensions 6 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 Figure 2 7 CAUTION Drum holes may be sharp from the machining process Burrs and sharp machined edges can cause s...

Page 21: ...rums In the process of staging the components for assembly there could be circumstances where the individual tubes have to be hand carried to the assembly site If the assemblers are unsure of the correct tube placement verify the correct location for each tube by measuring the second third or forth pass gap and cross reference with tube location figures in this chapter Figure 2 8 Use caution when ...

Page 22: ...vided by the downcomer pipe The pressure vessel will become progressively more rigid as additional tubes are installed Refer to pages 2 9 through 2 13 to determine the top and bottom of the tubes Install all of the tubes on one side of the boiler Install the inner row left side tube before the outer row tube Install the tubes in sequential order Begin installation of the left side tubes with a PAT...

Page 23: ...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 ferr...

Page 24: ...2 8 750 192 Figure 2 13 Both ends of the tube must be inserted prior to driving the tubes Figure 2 14 Use a modified vice grip to hold driving tool tight to the tube Figure 2 15 Tubes driven to uniform depth Figure 2 16 Completed Pressure Vessel ...

Page 25: ...93 3223 93 3234 P N TUBE 3 93 3202 93 3213 93 3224 93 3235 P N TUBE 4 93 3203 93 3214 93 3225 93 3236 P N TUBE 5 93 3204 93 3215 93 3226 93 3237 P N TUBE 6 93 3205 93 3216 93 3227 93 3238 P N TUBE 7 93 3206 93 3217 93 3228 93 3239 P N TUBE 8 93 3207 93 3218 93 3229 93 3240 P N TUBE 9 93 3208 93 3219 93 3230 93 3241 P N TUBE 10 93 3209 93 3220 93 3231 93 3242 P N TUBE 11 93 3210 93 3221 93 3232 93 ...

Page 26: ...2697 93 2708 93 2719 P N TUBE 3 93 2687 93 2698 93 2709 93 2720 P N TUBE 4 93 2688 93 2699 93 2710 93 2721 P N TUBE 5 93 2689 93 2700 93 2711 93 2722 P N TUBE 6 93 2690 93 2701 93 2712 93 2723 P N TUBE 7 93 2691 93 2702 93 2713 93 2724 P N TUBE 8 93 2692 93 2703 93 2714 93 2725 P N TUBE 9 93 2693 93 2704 93 2715 93 2726 P N TUBE 10 93 2694 93 2705 93 2716 93 2727 P N TUBE 11 93 2695 93 2706 93 271...

Page 27: ...NO 9 1 93 3208 1 93 9219 1 93 3230 10 TUBE PATTERN NO 10 15 93 3209 17 93 9220 24 93 3231 11 TUBE PATTERN NO 11 2 93 3210 2 93 9221 2 93 3232 Boiler Sizes 150 250 300 350 400 600 Assembly Part No 93 2729 93 2737 93 2738 ITEM DESCRIPTION REQ PART NO REQ PART NO REQ PART NO 1 TUBE PATTERN NO 1 3 93 2685 3 93 2696 3 93 2707 2 TUBE PATTERN NO 2 15 93 2686 17 93 2697 24 93 2708 3 TUBE PATTERN NO 3 1 93...

Page 28: ... NO 7 30 93 3239 8 TUBE PATTERN NO 8 3 93 3240 9 TUBE PATTERN NO 9 2 93 3241 10 TUBE PATTERN NO 10 30 93 3242 11 TUBE PATTERN NO 11 2 93 3243 Boiler Sizes 700 900 Assembly Part No 93 2730 ITEM DESCRIPTION REQ PART NO 1 TUBE PATTERN NO 1 4 93 2718 2 TUBE PATTERN NO 2 30 93 2719 3 TUBE PATTERN NO 3 1 93 2720 4 TUBE PATTERN NO 4 4 93 2721 5 TUBE PATTERN NO 5 30 93 2722 6 TUBE PATTERN NO 6 2 93 2723 7...

Page 29: ...N NO 7 36 93 3239 8 TUBE PATTERN NO 8 4 93 3240 9 TUBE PATTERN NO 9 3 93 3241 10 TUBE PATTERN NO 10 36 93 3242 11 TUBE PATTERN NO 11 3 93 3243 Boiler Sizes 1000 1200 Assembly Part No 93 3599 ITEM DESCRIPTION REQ PART NO 1 TUBE PATTERN NO 1 6 93 2718 2 TUBE PATTERN NO 2 36 93 2719 3 TUBE PATTERN NO 3 1 93 2720 4 TUBE PATTERN NO 4 6 93 2721 5 TUBE PATTERN NO 5 36 93 2722 6 TUBE PATTERN NO 6 3 93 272...

Page 30: ...r 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 adequat...

Page 31: ...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 as shown in Figures 2 19 2 20 and 2 21 CAUTION Model FLE boilers are equipped with two lifting lugs located on the upper drum The lugs should be used to li...

Page 32: ...capable of pressurizing the flooded pressure vessel to its design pressure will be required If any ferrule to drum joint leaks are apparent the affected ferrule will need to be driven deeper into 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 ...

Page 33: ...r inspection and servicing of the internal boiler components Casing panels must be installed and fastened together in a specific order to ensure a strong seal Casing panels are joined by bolts or studs and are sealed by an expanded PTFE gasket material In addition to applying the gasket a small amount of Teflon paste and high temperature sealant supplied with the Model FLE assembly kit is to be ap...

Page 34: ...3 2 750 192 Figure 3 1 Typical Hot Water Flextube Casing ...

Page 35: ...06 26 868 1506 28 868 1506 60 868 1506 96 868 1506 128 18 Capscrew hex hd 1 2 13x 1 1 2 lg 868 102 8 868 102 8 868 102 8 868 102 8 868 102 8 19 Capscrew hex hd 5 8 11x 1 1 2 lg 868 188 8 868 188 8 868 188 8 868 188 8 868 188 8 20 Screw self tapping x 1 lg 841 423 50 841 423 50 841 423 50 841 423 50 841 423 54 21 Locknut hex hd 3 8 869 510 118 869 510 124 869 510 180 869 510 232 869 510 284 22 Nut ...

Page 36: ...3 4 750 192 Figure 3 2 Typical Low Pressure Steam Flextube Casing ...

Page 37: ...1 2 lg 868 102 8 868 102 8 868 102 8 868 102 8 868 102 8 19 Capscrew hex hd 5 8 11x 1 1 2 lg 868 188 8 868 188 8 868 188 8 868 188 8 868 188 8 20 Screw self tapping x 1 lg 841 423 56 841 423 56 841 423 56 841 423 56 841 423 60 21 Locknut hex hd 3 8 869 510 128 869 510 130 869 510 188 869 510 252 869 510 308 22 Nut hex hd brass 869 27 12 869 27 12 869 27 12 869 27 12 869 27 12 23 Nut hex hd 869 144...

Page 38: ...3 6 750 192 Figure 3 3 Typical High Pressure Steam Flextube Casing ...

Page 39: ...68 102 8 868 102 8 868 102 8 868 102 8 868 102 8 19 Capscrew hex hd 5 8 11x 1 1 2 lg 868 188 8 868 188 8 868 188 8 868 188 8 868 188 8 20 Screw self tapping x 1 lg 841 423 50 841 423 56 841 423 56 841 423 56 841 423 60 21 Locknut hex hd 3 8 869 510 118 869 510 130 869 510 188 869 510 252 869 510 308 22 Nut hex hd brass 869 27 12 869 27 12 869 27 12 869 27 12 869 27 12 23 Nut hex hd 869 144 24 869 ...

Page 40: ...etainer stud Figure 3 6 Unfold the wetpack to cover the lower drum and tubes near the vent tube Cut a 4 inch slit in the wet pack wrap it around the base of the vent tube and then unroll it over the lower drum and tubes Figure 3 7 2 Install Backing Plates Remove Support Bracket Hot Water Units Only Remove the drum spreader Torch the support bracket to remove it from the upper drum Leave at least o...

Page 41: ...silicone where the end walls will contact the base After checking that the insulation is packed Figure 3 10 lift the large piece of the rear wall into posi tion Figure 3 11 Until the wall is in the correct ver tical position leave a gap between the tubes and the wall to keep the insulation from getting squished Set the wall section on top of the base Wedge the wall upright Apply Never Seez to the ...

Page 42: ... adhesive to fasten a strip of insulation to both of the inside edges of the wall where the smaller portion of the rear wall will be attached Figure 3 14 3 Move the corner section of the rear wall into position taking care not to let the insulation get caught in the joint Install the end plates connecting the pieces of wall together and remove the wedge After ensuring that the wall is flush with t...

Page 43: ... then center the wall in relation to the base angles Tighten the nuts and bolts on the bolt ing plates to secure the walls to the base 8 Attempt to slide a box cutter into all of the seams where insulation is visible If the knife is able to enter then gasses can escape Tighten the bolts and repeat the last three steps 9 Trim all of the visible insulation from the joints 10 If necessary use the wed...

Page 44: ... the lower drum to the centerline of the sight port Figure 3 18 3 19 2 Drill a 1 hole through the insulation in the center of the sight port parallel to the drum Figure 3 20 The tape measure is in approximately the same loca tion that the flame will be 3 Obtain a 1 OD tube x 16 long 3 4 conduit to use as a guide pipe Use the guide pipe as an applicator and add rigidizer solution part 872 00458 not...

Page 45: ...ea Pack the insulation inside the boiler around the guide pipe ensuring that the open ing in the guide pipe is still pointing toward the top of the tape measure Pack the insulation so that there are no gaps and if necessary fill any cavities using loose insulation removed from the drilling process After the insulation has been packed around the guide pipe remove the guide pipe Figure 3 23 NOTE The...

Page 46: ...Backing Plates As in step 3 install the front upper and lower back ing plates 7 Install Front Wall Section To install the front wall section repeat the same steps used to install the rear wall In a hot water unit the front wall will be one piece and the instal lation will be much easier but the front wall of a steam boiler will have two pieces just like the rear 8 Install Roof Panel Tidy the top o...

Page 47: ...the front ensure the walls are flush with the edges of the roof and tighten the bolts Repeat this step at the back Figure 3 29 30 Figure 3 27 Insulation Strip on the Top of the Front and Rear Walls Figure 3 28 Insulation on Inside Corners of Front and Rear Walls Figure 3 29 Attaching roof panel Note the side walls should have been secured to the boiler This photo does not show the wall Figure 3 30...

Page 48: ... door should be closed gently to keep the insulation on the front wall If the door will not close pull it open and tap down the insulation in the area that is preventing the door from clos ing Install washers and brass nuts to evenly pull the burner door into the opening Start at the side farthest from the hinges moving towards them as you tighten Look inside the opening If any insulation is visi ...

Page 49: ...ne If wedges are being used the cover should be tight to the side opposite the lugs ie If the wedges are on the front of the boiler the cover should be tight to the rear of the lift lug Attach the cover so that the side tight against the lug is screwed first Figure 3 36 Use a putty knife and clean the surface of the cover Figure 3 37 Figure 3 34 Filling the Gaps with Insulation Figure 3 35 Silicon...

Page 50: ...uld be packed to within 1 of the outer wall NOTE Use the excess pyrobloc from the cutout of the burner door to pack around the drums NOTE Do the following three steps after section 16 has been finished Apply a layer of silicone caulk 872 420 to all sur faces in contact with the metal Install the drum seal cover plates and secure them with the self drilling screws 842 1402 Insulate the steam vent w...

Page 51: ...00 of 1 1 2 blanket insulation at the rear of the boiler in the refractory on both sides Use a spray adhesive to hold the insulation in place Figure 3 43 Install 1 1 2 blanket insulation in front of the first 1 1 2 strip of insulation and on the refractory from the front wall to the 12 x 12 piece of insulation at the rear of boiler Figure 3 44 13 Install Pass Insulation Spray adhesive 94 475 on th...

Page 52: ...he end wall Figure 3 47 Use extra pieced of insulation to fill the gaps near the interior seams at the bottom of the front and rear walls After ensuring that the void is filled clean the area bottom left corner of Figure 3 43 Apply the expanded PTFE gasket 32 2560 to the boiler The gasket should be positioned approxi mately 1 8 Figure 3 48 from the inside edge of the frame Start at the front of th...

Page 53: ...of the panel while tapping the insulation into the panel After this is fin ished check that there are no holes between the insulation and the panel Figure 3 51 Place a gasket on the side of the panel It should go 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 ...

Page 54: ...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 Figure 3 58 Install the nuts and washers arou...

Page 55: ... panels by sliding the top under the roof casing and then swinging the bottom into the boiler and sliding it down over the bottom angle Install all panels in this manner Panels should be positioned so that they are centered with equal lengths of uncovered area at the ends Figure 3 60 Push the panels together and fix screws to the bot tom outside corners of the panels to ensure that they do not mov...

Page 56: ...Casing Assembly Model FLE Assembly 3 24 750 192 ...

Page 57: ... Tighten the mounting nuts evenly to achieve a uniform compression of the burner flange gasket Bolt on the burner support Smaller burners do not require this support and it will not be provided for them 2 Burner Connections Electrical and fuel connections to the burner must be made in accordance with all applicable state and local codes as well as any insurers requirements that may apply 3 Gas Tra...

Page 58: ...750 192 4 2 Figure 4 2 Fuel Train Components ...

Page 59: ...ibed Deviation from the recommended wiring layout could result in a shortage of required material Use the wiring diagram supplied with the boiler in conjunction with the illustrations in this manual for layout and wiring purposes Figure 4 3 Typical Conduit Layout with a Profire Burner on a Hot Water Flextube Boiler Figure 4 4 Typical Conduit Layout with a Profire Burner on a Steam Flextube Boiler ...

Page 60: ...4 4 750 192 Figure 4 5 Typical conduit layout ProFire burner on a hot water Flextube boiler ...

Page 61: ...750 192 4 5 Figure 4 6 Typical conduit layout ProFire burner on a steam Flextube boiler ...

Page 62: ...4 6 750 192 Figure 4 7 Nameplate locations hot water boiler ...

Page 63: ...750 192 4 7 Figure 4 8 Nameplate locations steam boiler ...

Page 64: ...e mail info cleaverbrooks com Web Address http www cleaverbrooks com ...