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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
WARNING: Improper installation, adjustment, alteration,
• 24-06
service or maintenance can cause property damage, injury,
• 24-07
or loss of life. For assistance or additional information, con-
sult a qualified installer, service agency or the gas suppli
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2
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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 O
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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
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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
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TABLE OF CONTENTS SECTION I - GENERAL INFORMATION Dimensional Information ............................................................................................................................................... 8 Ratings/Data .................................................................................................................................................................. 9 Locating the Unit . ................................................................................
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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 ................................
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8 Section I - General Information FIGURE 1: Dimensional Information
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TABLE I BOILER RATINGS/DATA (1) (2) (3) (4) Heating Water Boiler Weight Burner Net Pressure Net I=B=R Rating Surface Content w/ Water Gross Vent Input Boiler Horse- Firebox in (Sq. Ft.) (Gal.) (Lbs.) Output Dia. Model Power Volume Firebox (MBH) (In.) Sq. Ft. MBH MBH Oil Gas (Cu.Ft.) ("W.C.) Steam Water Steam Water Steam Water Steam Steam Water (GPH) (MBH) 24-03 10.2 342 1071 257 297 3.05 438 34.2 37.0 3.2 .33 44.5 66.0 1439 1618 7 24-04 14.1 471 1471 353 410 4.10 594 48.6 54.3 4.8 .38 53.0 75.0
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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 damage. boiler jacket of 24” 1. ALL EQUIPMENT is carefully manufactured, 2. FOR MINIMUM CLEARANCES to combustible inspected and packed. Our responsibility ceases materials, See Table II. upon delivery of crated boiler to the carrier in good condition. 3. PROVIDE ADEQUATE FOUNDATION for the 2. ANY CLAIMS for damage or shortag
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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 2 per 2,000 Btuh (70 sq. inch per gph.) (11 cm Failure to supply adequate air to the boiler per kw) of total input of all appliances in the will result in unsafe boiler operation. enclosure. D. CHIMNEY OR VENT C. PROVIDE AIR SUPPLY AND VENTILATION to The Series 24 boiler is designed for forced draft firing accommodate proper combustion. and may be used wit
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If the venting system is designed for positive or forced If the venting system is designed for negative pressure draft venting, the boiler, vent connector and stack will (natural draft), the boiler still operates with positive operate under positive pressure. Gas tight vent systems pressure in the chamber and up to the fixed damper on designed for pressure systems must be used to prevent the flue collar. However, if the venting system is larger flue by-product leakage. The vent height is u
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SECTION II - CAST IRON BLOCK ASSEMBLY ENSURE THAT THE ADHESIVE DOES CAUTION NOT COME IN CONTACT WITH THE NIPPLES OR NIPPLE PORTS. Boiler sections must be drawn-up on e. Clean nipples and nipple ports thoroughly with perfectly level surface or improper a de-greasing solvent. Use the Loctite #592 assembly may result. supplied to lubricate the nipples and nipple ports. Apply the lubricant to the nipples and A. FIELD ASSEMBLED SECTIONS — If the boiler nipple ports, then use a
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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 t
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BOILER SECTION IDENTIFICATION CODE F = FRONT SECTION WITH 4” SUPPLY TAPPING C = CENTER SECTION B = BACK SECTION WITH 4” SUPPLY TAPPING CX = CENTER SECTION WITH 4” TOP SUPPLY TAPPING NOTES: FOR BOILERS LESS TANKLESS HEATER, REPLACE THE “CT” SECTIONS WITH “C” SECTIONS. Figure 8: Se
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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 a
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tapped holes in the front section. Be sure to g. After all sections have been drawn up, but before screw draw-up rods into couplings far enough to removing the hydraulic rams and draw-up rods, prevent stripping threads. the 9¾” long tie rods must be installed. d. Place a 3” x 12” lg. steel channel on each end of The large draw-up rod lugs with dual holes the upper draw-up rod and a 3” x 8½” lg. steel are cast in the four (4) corners of each casting. channel on each end of the lower draw-u
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Figure 12: Hydraulic Draw-Up of Sections B. HYDROSTATIC TEST — After the boiler sections 4. EXAMINE BOILER CAREFULLY, INSIDE AND have been assembled, it is essential that the boiler be OUTSIDE, to insure against leaks from cocked hydrostatically tested before the canopy, flue cover nipples or through concealed breakage caused in plates, jacket, or piping is installed. shipping and handling. This precaution is for your protection and will simplify handling of necessary 1. Tankless Heater
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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 s
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20 Figure 16: Bare Boiler Assembly
