CleaverBrooks FLE User manual

Model FLE
Assembly Instructions
750-192
07/09
Field Erectable Flexible Watertube Boiler

ii
!DANGER
WARNING
If the information in this manual is not fol-
lowed exactly, a fire or explosion may re-
sult causing property damage, personal
injury or loss of life.
— Do not store or use gasoline or other
flammable 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, or
maintenance can cause equipment damage,
personal injury, or death. Refer to the Opera-
tion and Maintenance manual provided with
the boiler. Installation and service must be
performed by a qualified Cleaver-Brooks ser-
vice provider.
!DANGER
WARNING
!DANGER
WARNING
Be sure the fuel supply which the boiler
was designed to operate on is the same
type as specified 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 boiler and to replace any part of
the control system and any gas control
which has been under water.
!DANGER
WARNING
To minimize the possibility of serious per-
sonal injury, fire or damage to the equip-
ment, never violate the following safety
rules.
—Alwayskeeptheareaaroundtheboiler
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 the
boiler or in a safe place for future refer-
ence. Contact your local Cleaver-Brooks
representative if additional manuals are
required.
Notice
Where required by the authority having
jurisdiction, the installation must conform
to the Standard for Controls and Safety
Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
Notice

iii
The installation must conform to the re-
quirementsof theauthorityhaving jurisdic-
tion or, in the absence of such
requirements, 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

iv
Notes

v
Please direct purchase orders 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

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 the
components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe
personal injury or death.
It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who
are 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 electrical
and 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 and
hazards inherent in handling and firing of fuel.
Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely
free 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 instructions
can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the
responsibility 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 vary
considerably 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 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 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 the
need 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 stoppages
which could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected
frequently 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 proper
boiler water treating practices.
The operation of this equipment by the owner and his or her operating personnel must comply with all requirements or
regulations 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 SEVERE
PERSONAL INJURY OR DEATH.
!DANGER WARNING

vii
CONTENTS
CHAPTER 1
General Description
1. The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Transportation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
3. Order of Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
4. Pressure Vessel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
5. Casing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
6. Burner and Fuel Piping Installation . . . . . . . . . . . . . . . . . . . . . 1-7
7. Trim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
CHAPTER 2
Pressure Vessel Assembly
1. Preparation for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2. Position the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3. Level the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
4. Positioning the Lower Drum on the Base . . . . . . . . . . . . . . . . . 2-3
5. Upper Drum Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
6. Check All Drum Holes and Studs . . . . . . . . . . . . . . . . . . . . . . 2-4
7. Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
8. Ferrule Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
9. Pass Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
10. Installation of Pressure Vessel to Base . . . . . . . . . . . . . . . . 2-16
11. Pressurized Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
CHAPTER 3
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 Plates . . . . . . . . . . . . . . . . . 3-18
12. Install Insulation Under Tubes . . . . . . . . . . . . . . . . . . . . . . 3-19
13. Install Pass Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
14. Prepare for Inner Casing Installation . . . . . . . . . . . . . . . . . . 3-20
15. Prepare Inner Panels for Installation . . . . . . . . . . . . . . . . . 3-21
14. Install Inner Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
17. Install Outer Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
CHAPTER 4
Burner Assembly, Gas Train, and Boiler Controls Installation
1. Burner Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
2. Burner Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
3. Gas Train Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4. Electrical Connections and Layout . . . . . . . . . . . . . . . . . . . . . 4-3

viii

Model FLE Assembly General Description
750-192 1-1
CHAPTER 1
General Description
1. The Boiler . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Transportation and Handling . . . . . . . . . . . 1-2
3. Order of Assembly . . . . . . . . . . . . . . . . . . 1-4
4. Pressure Vessel Assembly . . . . . . . . . . . . . 1-4
5. Casing Assembly . . . . . . . . . . . . . . . . . . . 1-5
6. Burner and Fuel Piping Installation . . . . . . . 1-7
7. Trim Installation . . . . . . . . . . . . . . . . . . . . 1-7
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. Five-Pass Construction of the Cleaver
Brooks Model FLE Boiler
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. In the fifth pass, the gases flow around the
top drum before exiting the boiler casing through the
stack vent.

General Description Model FLE Assembly
1-2 750-192
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. Model FLE Boiler Tubes Being Readied
to Ship
Table 1-1: Boiler Components, Approximate Weights and Sizes
PARTS HOT WATER
DESCRIPTION INFO 150-250 300-350 400-600 700-900 1000-1200
Base Assembly PART NO 315-1124 315-1169 315-1180 315-1194 315-1203
(Insulated) APPROX. SIZE (in) 68x42 74x45-1/2 94-1/5x47-1/2 116x53-1/2 140x53-1/2
WEIGHT (lbs) 630 710 950 1440 1690
Front Wall PART NO 315-1128 315-1265 315-1177 315-1191 315-1201
APPROX. SIZE (in) 68x33-1/2 77x40 77x40 84x45 84x45
(Insulated) WEIGHT (lbs) 110 130 140 175 175
Rear Wall PART NO 315-1129 315-1165 315-1176 315-1190 315-1190
Large Piece APPROX. SIZE (in) 67x33-1/2 77x40 77x40 84x45 84x45
(Insulated) WEIGHT (lbs) 110 125 140 175 175
Rear Wall PART NO 315-1140 315-1279 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 20x102-1/2 20x126-1/2
WEIGHT (lbs) 320 340 540 620 690
Lower Drum PART NO 270-2708 270-2709 270-2710 270-2711 270-2712
Assembly APPROX. SIZE (in) 14x55 16x60-1/4 17x81-1/4 20x102-1/2 20x126-1/2
WEIGHT (lbs) 300 230 510 590 660
Inner Casing PART NO * * * * *
Panels APPROX. SIZE (in) 67x32 74x36 79x28 86x30 86x28
(Insulated) WEIGHT (lbs) 50 53 57 61 61
Outer Casing PART NO 315-1130 315-1164 315-1175 315-1189 315-1198
Panels APPROX. SIZE (in) 71x22 75x24 80x23 87x27 87x25
(Insulated) WEIGHT (lbs) 38 43 40 39 38
Burner Door PART NO ** ** ** ** **
APPROX. SIZE (in) 20x20 20x20 26x26 26x26 26x26
WEIGHT (lbs) 120 120 240 240 240
Tubes PART NO ** ** ** ** **
APPROX. SIZE (in) 14x28-1/2 16x31-1/2 17x43.5 20x51.75 20x63.75
WEIGHT (lbs) 1300 2000 2300 3300 4000
TOTAL WEIGHT 3900 5000 7600 8500 10000
* Various part numbers are used for each size
** Part number depends on burner size required.

Table 1-1 cont’d
PARTS HIGH PRESSURE STEAM LOW PRESSURE STEAM
DESCRIPTION INFO 150-250 300-350 400-600 700-900 1000-1200 150-250 300-350 400-600 700-900 1000-1200
Base Assembly PART NO 315-1224 315-1169 315-1180 315-1194 315-1203 315-1224 315-1169 315-1180 315-1194 315-1203
(Insulated) APPROX. SIZE (in) 60x42 74x45-1/2 95x47-1/2 116x53-1/2 140x53-1/2 60x42 74x45-1/2 95x47-1/2 116x53-1/2 140x53-1/2
WEIGHT (lbs) 630 710 950 1440 11690 630 710 950 1440 11690
Front Wall PART NO 315-1216 315-1229 315-1238 315-1249 315-1249 315-1216 315-1229 315-1238 315-1249 315-1249
Large Piece APPROX. SIZE (in) 77x33 81x37 85x39 97x45 97x45 77x33 81x37 85x39 97x45 97x45
(Insulated) WEIGHT (lbs) 110 125 125 170 170 110 125 125 170 170
Front Wall PART NO 315-1286 315-1288 315-1290 315-1292 315-1292 315-1286 315-1288 315-1290 315-1292 315-1292
Corner Piece APPROX. SIZE (in) 32x17 36x19 34x20 40x23 40x23 32x17 36x19 34x20 40x23 40x23
(Insulated)WEIGHT(lbs)20253035352025303535
Rear Wall PART NO 315-1217 315-1228 315-1237 315-1248 315-1248 315-1217 315-1228 315-1237 315-1248 315-1248
Large Piece APPROX. SIZE (in) 77x33 81x37 85x40 97x46 97x46 77x33 81x37 85x40 97x46 97x46
(Insulated) WEIGHT (lbs) 130 145 155 210 210 130 145 155 210 210
Rear Wall PART NO 315-1285 315-1287 315-1289 315-1291 315-1291 315-1285 315-1287 315-1289 315-1291 315-1291
Corner Piece APPROX. SIZE (in) 40x21 44x23 42x24 40x23 40x23 40x21 44x23 42x24 40x23 40x23
(Insulated)WEIGHT(lbs)25303540402530354040
Roof Assembly PART NO 315-1215 315-1230 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 20x126 24x150 24x182
WEIGHT (lbs) 890 930 1075 1500 1750 975 1020 1170 1660 1910
Lower Drum PART NO 270-1519 270-1520 270-1521 270-1522 270-2513 270-1515 270-1516 270-1517 270-1518 270-2581
Assembly APPROX. SIZE (in) 8x96 8x104 10x126 10x150 10x182 8x96 8x104 10x126 10x150 10x182
WEIGHT (lbs) 310 325 515 600 705 310 325 515 600 705
Inner Casing PART NO **********
Panels APPROX. SIZE (in) 76x32 83x35 87x32 100x30 100x28 76x32 83x35 87x32 100x30 100x28
(Insulated)WEIGHT(lbs)57606355555760635555
Outer Casing PART NO 315-1218 315-1227 315-1236 315-1247 315-1257 315-1218 315-1227 315-1236 315-1247 315-1257
Panels APPROX. SIZE (in) 80x22 84x23 88x23 100x23 100x23 80x22 84x23 88x23 100x23 100x23
(Insulated)WEIGHT(lbs)42484345444248434544
Burner Door PART NO ** ** ** ** ** ** ** ** ** **
APPROX. SIZE (in) 20x20 20x20 26x26 26x26 26x26 20x20 20x20 26x26 26x26 26x26
WEIGHT (lbs) 120 120 240 240 240 120 120 240 240 240
Tubes PART NO 93-3200 93-3200 93-3200 93-3200 93-2729 93-3200 93-3200 93-3200 93-3200 93-2729
APPROX. SIZE (in) 25-3/4x60 29-37x64 36-3/4x67 38-3/4x77 38-3/4x77 25-3/4x60 29-37x64 36-3/4x67 38-3/4x77 38-3/4x77
WEIGHT (lbs) 1400 1700 2500 3600 4400 1400 1700 2500 3600 4400
TOTAL WEIGHT 5700 5700 6200 7900 10200 11700 6200 7900 10200 11700
* Various part numbers are used for each size
** Part number depends on burner size required.

General Description Model FLE Assembly
1-4 750-192
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.
Assembly of the boiler can be regarded as a four
step process. The four steps 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)
4. Trim 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
• 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
•Boilertubes
• Base assembly
• Ceramic fiber pass seal insulation
• Tube sealant (LockTite 680)
• Anti-seize lubricant
• Tube retainers and fasteners
• Spray adhesive
Figure 1-3. ProFire burner mounted on a Model FLE
boiler
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)

Model FLE Assembly General Description
750-192 1-5
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 build a rhythm allowing
for the installation of a side of 40 tubes in two to
four hours.
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)

General Description Model 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)
1 234
5

Model FLE Assembly General Description
750-192 1-7
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
•Conduitandwire
• Pipe components
• Standard electrical tools (conduit bender, wire puller,
etc.)
•Wiringdiagram
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 or
rear walls to allow ventilated mounting space for the
required safety and warning stickers.

General Description Model FLE Assembly
1-8 750-192

Model FLE Assembly Pressure Vessel Assembly
750-192 2-1
CHAPTER 2
Pressure Vessel Assembly
1. Preparation for Assembly . . . . . . . . . . . . . 2-1
2. Position the Base . . . . . . . . . . . . . . . . . . . 2-3
3. Level the Base . . . . . . . . . . . . . . . . . . . . . 2-3
4. Positioning the Lower Drum on the Base . . . 2-3
5. Upper Drum Placement . . . . . . . . . . . . . . 2-4
6. Check All Drum Holes and Studs . . . . . . . . 2-4
7. Tube Installation . . . . . . . . . . . . . . . . . . . 2-6
8. Ferrule Retainers . . . . . . . . . . . . . . . . . . 2-14
9. Pass Seals . . . . . . . . . . . . . . . . . . . . . . . . 2-5
10. Installation of Pressure Vessel to Base . . 2-16
11. Pressurized Leak Test . . . . . . . . . . . . . . 2-16
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 processes. 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.
WA RN I NG
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.

Pressure Vessel Assembly Model FLE Assembly
2-2 750-192
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 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 69-1/2 182 172-1/2
1200 77 69-1/2 182 172-1/2

Model FLE Assembly Pressure Vessel Assembly
750-192 2-3
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
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 front.
NOTE: Whenever bolts are used, apply
“Never Seez”. Hand tighten the bolts
and when everything is in the desired
position, tighten completely. This pro-
cedure is to be used for ALL bolts.
Figure 2-3. Front (left) and Rear (right) of the base
Figure 2-4. Bolting upper drum to downcomers
Figure 2-5. Continually check level as vessel is
being assembled
3 layers of
insulation
under lower
drum, front
and rear

Pressure Vessel Assembly Model FLE Assembly
2-4 750-192
5. Upper Drum Placement
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 the boiler 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 2-6. The part numbers for the 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 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
the assembly process go smoother. All retainer
studs must be coated with “Never-Seez”.
Figure 2-6. Drum spreader in position on completed
vessel
Figure 2-7. Use a 5/8" die to chase all the retainer
stud threads
Table 2-2 Drum Spreader Part Numbers for Hot Wa-
ter Units by Size
Size Part No.
150-250 98-317
300-350 98-323
400-600 98-318
700-1200 98-324