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SECTION I - GENERAL INFORMATION

Dimensional Information ............................................................................................................................................. 10

Ratings/Data ................................................................................................................................................................ 11

Locating the Unit . ........................................................................................................................................................ 12

Air Supply/Venting ....................................................................................................................................................... 13

SECTION II - CAST IRON BLOCK ASSEMBLY (Knockdown Only)

Assembly of Sections, Manual Draw-up ..................................................................................................................... 19

Assembly of Sections, Hydraulic Draw-up ................................................................................................................. 21

Hydrostatic Test ........................................................................................................................................................... 23

SECTION III - INSTALLATION INSTRUCTIONS

Knockdown

Canopy ......................................................................................................................................................................... 25

Flue Cover Plates ......................................................................................................................................................... 26

Rear Observation Port Cover ........................................................................................................................................ 26

Inspect All Boiler Seals ................................................................................................................................................ 26

Ceramic Fiber Firewall Plates ...................................................................................................................................... 26

Jacket Assembly .......................................................................................................................................................... 27

Burner Mounting Plate / Burner Adapter Plate ........................................................................................................... 32

Steam Trim .................................................................................................................................................................. 32

Water Trim . .................................................................................................................................................................. 34

Burner Installation ....................................................................................................................................................... 35

Package Boilers

Preparation for Installation ........................................................................................................................................... 35

Common Installation Requirements

Boiler Piping - Heating Applications .......................................................................................................................... 35

Boiler Piping - Steam Applications .............................................................................................................................. 37

Boiler Piping - Domestic Hot Water (DHW) Applications .......................................................................................... 46

Tankless Heater Piping ................................................................................................................................................ 47

Electric Wiring .............................................................................................................................................................. 48

SECTION IV - OPERATING INSTRUCTIONS

Filling System ............................................................................................................................................................... 52

Adjusting Controls ....................................................................................................................................................... 53

Adjusting Burner ......................................................................................................................................................... 53

Test Controls ................................................................................................................................................................ 53

Initial Cleaning, Steam Boilers .................................................................................................................................... 53

Initial Cleaning, Water Boilers .................................................................................................................................... 55

Frequent Water Addition .............................................................................................................................................. 55

Oxygen Corrosion ........................................................................................................................................................ 56

SECTION V - SERVICE INSTRUCTION

Cleaning Boiler Heating Surfaces ............................................................................................................................... 57

Maintenance of Low Water Cutoff Devices ................................................................................................................ 58

Checking Burner & Controls ........................................................................................................................................ 59

Lubrication ................................................................................................................................................................... 59

General Maintenance Considerations ........................................................................................................................... 59

Attention to Boiler While Not in Operation ................................................................................................................. 59

SECTION VI - BURNER SPECIFICATIONS

Beckett Burners (Table VI) ...........................................................................................................................................60

Power Flame Burners (Table VII) ................................................................................................................................61

Webster Burners (Table VIII) .......................................................................................................................................64

Carlin Burners (Table IX) .............................................................................................................................................67

SECTION VII - REPAIR PART

Regional Ofce Directory ............................................................................................................................................ 68

Jacket Assembly .......................................................................................................................................................... 69

Bare Boiler Assembly ................................................................................................................................................... 73

Steam/Water Trim ......................................................................................................................................................... 77

WARRANTY ....................................................................................................................................................... REAR COVER

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