dynatherm FP Series User manual

43 E. Cherry Rd. | Quakertown, PA 18951 | Ph: 215-536-4078 | Fx: 215-536-8960 | Email: [e-mail]
INSTALLATION & OPERATION MANUAL
Dynatherm™Since 1937
Residential Boilers, Heating & Domestic Hot Water Systems
• OIL-FIRED
• PROPANE-FIRED
• NATURAL GAS-FIRED
Dynatherm™ FP Series Boiler
Models: FP18, FP24, FP36 & FP48
(Optional)
WARRANTY
This boiler has a limited lifetime warranty. A warranty card is included with your new boiler packet. Please note
your serial number, date of installation and contractor’s information below.
SERIAL NUMBER:
DATE:
CONTRACTOR:
PHONE:

TABLE OF CONTENTS
BEFORE GETTING STARTED..................................................................................................................................5
GENERAL DESCRIPTION........................................................................................................................................7
BOILER DESCRIPTION & OPERATION ...................................................................................................................7
BURNER DESCRIPTION .........................................................................................................................................8
CONTROLS DESCRIPTION .....................................................................................................................................8
FP SERIES BOILER SPECIFICATIONS ......................................................................................................................9
BILL OF MATERIALS........................................................................................................................................... 10
FP SERIES BOILER LAYOUT ................................................................................................................................ 11
BOILER INSTALLATION ...................................................................................................................................... 12
LOCATION...................................................................................................................................................... 13
LEVELING....................................................................................................................................................... 14
JACKETING..................................................................................................................................................... 14
PIPING ........................................................................................................................................................... 14
DOMESTIC HOT WATER COIL........................................................................................................................ 15
VENTILATION & CHIMNEY CONNECTIONS.................................................................................................... 17
FUEL SUPPLY ................................................................................................................................................. 18
ELECTRICAL WIRING...................................................................................................................................... 18
INITIAL BURNER SETUP & START-UP............................................................................................................. 18
BOILER MAINTENANCE ..................................................................................................................................... 19
INSPECTION................................................................................................................................................... 19
DISASSEMBLY................................................................................................................................................ 19
REASSEMBLY ................................................................................................................................................. 19
CLEANING PROCEDURE................................................................................................................................. 20
TROUBLESHOOTING.......................................................................................................................................... 21
BURNER CONFIGURATIONS .............................................................................................................................. 22
RATINGS AND APPROVALS................................................................................................................................ 25
NOTES................................................................................................................................................................ 27

Page | 5
BEFORE GETTING STARTED
⚠WARNING
Installation must conform to the following:
Local, state and national codes, laws, regulations and ordinances.
National Fuel Gas Code, ANSI Z223.1 latest version.
National Electric Code, ANSI/NFPA-70 latest revision.
Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1 latest
revision, when required.
Read this manual in its entirety before attempting installation, start-up or service.
Proper operation depends on following all instructions carefully, including those contained within the
manufacturers’ components that are provided with your boiler.
This boiler contains extremely hot water under pressure and failure to follow all instructions could cause
personal injury, property damage or death.
Dynatherm™ boilers must be installed, serviced, maintained, repaired, upgraded and/or modified only by
a qualified Dynatherm™ installer/technician.
A qualified Dynatherm™ installer/technician is an individual who has been properly trained on installing
and servicing Dynatherm™ boilers and must be a licensed installer.
Homeowners should never attempt to install, service, repair, upgrade or modify the Dynatherm™ boiler.
Dynatherm™ boilers must be installed by a qualified installer/technician in order to validate the warranty.
Verify you have the correct size boiler for your home and/or application. Refer to the DOE & IBR ratings
chart found in the FP Series Boiler Specification section of this this manual.
This boiler requires regular yearly maintenance and service to operate properly and safely.

Page | 6

Page | 7
GENERAL DESCRIPTION
The Dynatherm™ FP Series Boiler is a high quality
fabricated steel & cast iron boiler of the Scotch
Marine Design, long recognized as the most
efficient boiler design in its size category. It will
provide years of economical heat and domestic
hot water when properly installed and cared for.
Therefore, it is important that these instructions
be followed carefully.
The Dynatherm™ boiler comes with an insulated
jacket and a burner package. Each burner
package includes the following items:
1) Burner
2) Air Tube/Flange/Gasket
3) Nozzle
4) Harness Assembly
5) Temperature/Pressure Gauge
6) Pressure Relief Valve
7) Aquastat
8) Smoke/Flue Cap
9) Bolts/Nuts/Hardware
10) Manufacturer’s Warranty Package
Dynatherm™ boilers are shipped skidded or can
be picked up directly un-skidded. The burner
package and jacket are boxed separately. Upon
receiving your items, all packages/items should be
inspected for signs of damage. If shipped, any
damage should be noted on the carrier’s waybill.
Keep all damaged packages/items and request an
inspection by the carrier. It’s the responsibility of
the consignee to file any claims with the
delivering carrier for any damaged items received.
Claims must be submitted within five (5) days
after receipt. No claims will be accepted after this
five (5) day period.
BOILER DESCRIPTION & OPERATION
Dynatherm™ is America's only residential steel
and cast iron belly flue, three pass Scotch Marine
boiler. It’s designed to force hot gases through
the boiler in three passes while maintaining the
highest efficiency ratings.
The first pass drives the hot gases of combustion,
which are produced by the burner at the front
head, through the combustion tube into the end
head, which houses our exclusive scroll. As the
gases enter the end head, they’re separated into
the 13 curls of the scroll and
spun at a greatly increased
velocity into the 13 fire
tubes that surround the
combustion tube. The scroll
is designed to reverse the
spin of the whirling gases
from clockwise to
counterclockwise, which slows the
gases down by 2-1/2 –3 times. This allows the
heat to remain inside the boiler much longer.
The second pass forces the swirling gases through
the 13 fire tubes in a slow counterclockwise
motion, causing a scrubbing action. This causes a
dual effect. First, the gases travel through the fire
tubes in a curling pattern, which causes the heat
to be retained inside the fire tubes 2-1/2 –3
times longer. Due to the longer retention, this
gives the gases a longer period of time to transfer
the heat (BTU’s) through the fire tubes into the
surrounding water inside the boiler shell. Second,
the action caused by these gases creates a
scrubbing effect which greatly enhances the
efficiency of heat transfer from the gases into the
fire tube walls.
The third pass creates the gases third rotation as
they enter the front head. Heat naturally tries to
rise, so our boiler is designed to force all the heat
downward into the third pass chamber (belly
pan). This process allows the most efficient
transfer of heated gases into the belly pan.
This three pass Scotch Marine design utilizes all
the BTU’s that are input through direct contact of
gases to the heating surfaces, allowing the
maximum available heat to transfer into the
boiler water. As a result of this process, the
Dynatherm™ boiler has a proven efficiency rating
up to 90.9% with low stack temperatures ranging
from 240°F to 370°F.
Scroll

Page | 8
BURNER DESCRIPTION
Riello and Carlin are the only two burner
manufacturers recommended by Dynatherm™.
Refer to the Burner Configurations section in this
manual to identify the most suitable burner and
model for your boiler.
Retrofit kits are available for older, compatible
burners, such as the original Dynatherm, that are
installed on your boiler.
Refer to the manufacturer’s Installation Manual
for proper installation and settings.
CONTROLS DESCRIPTION
Fuel-fired hot water boilers and associated
controls have evolved over the years to a point at
which they are extremely safe and will operate
automatically in your home.
Dynatherm™ boilers are equipped with a Fuel
Smart Hydrostat 3200-Plus/3250-Plus aquastat.
This unit serves as the boiler water sending unit.
The high temperature, low temperature and
temperature differential are set digitally on this
unit.
Refer to the manufacturer’s Installation Manual
for proper installation and settings.
NOTICE
Only a qualified Dynatherm™ installer/technician should install, service, set or adjust these units.

Page | 9
FP SERIES BOILER SPECIFICATIONS
MODEL
FIRING
RATE
DOE
HEATING
CAPACITY
NET IBR
RATING
WATER
EFFICIENCY
STEADY STATE
HEAT
TRANSFER
SURFACE
WATER
CONTENT
DOMESTIC
HOT WATER
COIL GPM
STACK
TEMP
NO
GPH
MBH
MBH
SQ FT
COMB
AFUE
SQ FT
GAL
P1
P2
GR
NET
CO2
FP18
0.65
81.7
71
484
89.1
87.3
19.0
19
5
1.8
290
230
13%
0.85
105.4
92
611
88.2
86.1
19.0
19
5
2.3
325
265
1.00
121.7
106
706
86.7
84.5
19.0
19
5
2.7
370
310
FP24
0.85
106.7
93
620
89.2
87.2
23.5
25
5
2.3
240
180
13%
1.00
123.7
108
720
88.1
85.9
23.5
25
5
2.7
275
215
1.25
152.1
132
880
86.5
83.9
23.5
25
5
3.3
350
290
FP36
1.25
159.3
139
927
90.5
88.5
32.5
38
6
3.4
260
200
13%
1.35
170.9
149
993
89.9
87.9
32.5
38
6
3.7
285
225
1.50
187.9
164
1093
89.0
87.0
32.5
38
6
4.1
325
265
FP48
1.65
209.0
167
1119
90.9
88.9
41.5
52
6
4.5
250
190
13%
2.00
253.0
182
1213
90.0
88.0
41.5
52
6
4.9
290
230
2.25
285.0
201
1340
88.8
86.8
41.5
52
6
5.3
320
26
* P1 is the coil capacity at 180°F, intermittent draw. Use these ratings to compare with boilers.
* P2 is the ability to heat water from 40°F to 140°F, without interruption, at the intended flow.
* DOE is the annual fuel use efficiency.
FLUE & FITTINGS
MODEL
“A”
“B”
“C”
WEIGHT
INSTALLATION CLEARNACE
FLUE
CHIMNEY
OUTLET
NO
LENGTH
WIDTH
HEIGHT
LBS
TOP
SIDE
FRONT
REAR
(DIA)
(MIN)
RETURN
FP18
36.5”
18.5”
35”
500
6”
12”
24”
20”
5”
6” RD
OR
6” SQ
1.25” NPT
OR
1.5” NPT
OR
2” NPT
FP24
42.5”
18.5”
35”
555
6”
12”
24”
26”
5”
FP36
54.5”
18.5”
35”
665
6”
12”
24”
38”
5”
FP48
66.5”
18.5”
35”
775
6”
12”
24”
50”
5”

Page | 10
BILL OF MATERIALS
ITEM DESCRIPTION PART NO.
1 Boiler Shell N/A
2 Front Tube Sheet N/A
3 Rear Tube Sheet N/A
4 Fire Tubes - FP18 306.000
FP24 306.010
FP36 306.020
FP48 306.040
5 Combustion Tube N/A
6 Liner, Combustion Tube 503.012
7 Tankless Coil - FP18 500.000
FP24 500.010
FP36 500.020
FP48 500.040
8 End Head, 70L 920.003
9 Refractory Insert, Target 921.000
10 Frame, 3” Peephole 100.315
11 Glass, Peephole 102.316
12 Gasket, Peephole 100.317
13 Slide, Peephole 202.102S
14 Lever, Peephole 202.102L
15 Front Head, 69U 200.101
16 Aquastat C483250
17 Third Pass Chamber N/A
18 Flue Connection N/A
19 Scroll 210.000
20 Temperature/Pressure Gauge 502.001
21 Jacket - FP18 975.000
FP24 975.010
FP36 975.020
FP48 975.030
22 Gasket, Rope 3/8” 100.300B
23 Gasket, Rope 1/2" 100.300A
24 Air Tube Insulator 960.001
25 Inspection Plate 211.000
26 Gasket, Inspection Plate 100.003
27 Gasket, Coil 100.001
28 Burner N/A
29 Gasket, Burner Adapter 100.202
30 Pressure Relief Valve 422.001

Page | 11
FP SERIES BOILER LAYOUT

Page | 12
BOILER INSTALLATION
⚠DANGER
Keep the boiler area clean and free from
combustible materials, gasoline and other
flammable liquids and vapors.
Avoid installing and operating the boiler in an
environment where saw dust, loose insulation
fibers, dry wall dust, etc. are present.
⚠IMPORTANT
Be sure to wear protective clothing and gear when installing this boiler to prevent injury.
All seals must be air tight and all enclosure plates must be in place at all times. The seals consist of the
peephole gasket, rope gaskets, inspection plate gasket and the burner gasket. Leaks in these seals will
result in the improper operation of the boiler, which can cause smoke and/or poor CO2levels. Under no
circumstances should you use boiler cement to seal a gasket joint.
This boiler needs fresh air for safe operation and must be installed so there is proper combustion and
ventilation.
This boiler must be properly vented, either direct vent or chimney vent.
A pressure relief valve must be installed on this boiler.
The combustion tube liner and the air tube insulator must be installed directly against the front head,
prior to starting the burner. The combustion tube liner is used to provide protection for the combustion
tube and assists with maintaining smokeless combustion, while the air tube insulator protects the air
tube.
The burner operation can be observed through the peephole located on the end head. The cast iron lever
can be conveniently rotated to one side of the peephole in order to view the fire/flame. The lever must
be returned to cover the glass when not in use.
If your boiler is being used for domestic hot water, a temperature limiting valve/thermostatic mixing
valve must be installed to prevent burns or scalding. Selection and installation must comply with the
valve manufacturer’s recommendations and instructions. Check with the local authority having
jurisdiction for regulations. Mixing valves are not included with your boiler package nor are these valves
supplied or sold by Dynatherm™.
The tankless domestic hot water coil is positioned in the hottest boiler water inside the boiler shell, just
above the fire tubes. This provides an immediate response to domestic hot water requirements.

Page | 13
LOCATION
1. The boiler must be located on a rigid, non-
combustible floor or base such as cement,
tile, brick etc.
a. A suitable enclosure, usually a basement,
is a desirable location.
2. Check to make sure the area is free and clear
from any combustible materials, surfaces or
flammable liquids, and make sure there is
plenty of room around the boiler for fresh air.
3. The water return and flue can be piped from
either side of the boiler.
4. The recommended base size and necessary
clearance distances from the edge of the
boiler to any combustible surface, chimney or
any other obstruction is indicated below.
BOILER
SIZE
BASE DIMENSIONS
MINIMUM CLEARNACE
WIDTH (A)
LENGTH (B)
BURNER END (C)
COIL END (D)
TOP (E)
SIDE (F)
FP18
28”
50”
24”
20”
6”
12”
FP24
28”
56”
24”
26”
6”
12”
FP36
28”
70”
24”
38”
6”
12”
FP48
28”
92”
24”
50”
6”
12”
Figure 1
The above chart shows the absolute minimum clearance needed. As an additional safety measure,
Dynatherm™ recommends a minimum of 24” at the front end (burner end), 48” at the rear end (coil end),
and 12” from the top and sides of the boiler for ideal working access.

Page | 14
LEVELING
1. The boiler should be shimmed level.
2. If the floor is damp, it’s recommended that the
boiler be supported on blocks or framing with
a non-oxidizing material (brick, slate, etc.)
above the floor for ease of servicing and to
minimize piping and flue connection
requirements.
JACKETING
1. Verify that the three jacket panels in the box
are the correct size for your boiler. There
should be one top, one left and one right side
panel.
2. Attach the two side panels first and then the
top jacket to overlap the side panels.
a. Use the bolts, nuts and sheet metal
screws provided to fasten the panels to
the boiler.
3. Depending on which side of the boiler you’re
connecting the water return and exhaust to,
punch out the perforated openings on the
side jacket so you’ll have access. Don’t forget
to cap the flue opening that you aren’t using
with a flue cap.
4. Once the jacket panels are installed, affix the
appropriate safety label(s) to the outside of
the jacket and make sure they’re located in
plain sight.
a. These safety labels are included with your
new boiler packet.
PIPING
1. Make sure the jacket top is installed on the
boiler before connecting any piping. If it’s
not, install the top jacket first.
2. Connect piping to the water riser on top of
the boiler and the water return on the
bottom of the boiler.
a. The riser should run a vertical distance of
a least 12” above the boiler outlet.
b. The return must run horizontally and be
at least 14” from the center of the boiler
to clear the side jacket panels. A 2” NPT X
12” male pipe nipple is recommended.
c. See Figure 2.
Figure 2
3. The unused water return connection should
be plugged and/or used as a boiler drain.
4. Install a pressure relief valve on top of the
boiler next to the water riser.
a. If a domestic hot water coil is installed on
the boiler, a separate pressure relief valve
should be installed on that line in
accordance with local codes.
5. Connect a discharge pipe to the pressure
relief valve(s) and direct the piping downward
toward the floor.
a. The pressure relief valve(s) and discharge
pipe(s) should be installed in accordance
with local codes.
6. A water make-up circuit should be installed
with the boiler.
7. Fill the boiler and system with water and
check for leaks.
a. If leaks are detected, drain the water and
address the leaks.
b. If no leaks are detected, add boiler water
treatment compounds as recommended

Page | 15
by your local qualified water treatment
company.
c. Dynatherm™ recommends the water to
be maintained at 85 pH.
⚠CAUTION
If the boiler is being fired without being full of
water, the tubes can loosen and leak. This is a
negligent operation and is not covered under
the warranty.
8. All piping should be done in a neat,
workmanlike manner to compliment the
boiler. The design of the piping is pertinent to
each job and is the responsibility of the
installer.
9. See Figures 3, 4 & 5 below for suggested
general piping diagrams.
DOMESTIC HOT WATER COIL
1. If a tankless domestic hot water coil is
installed on the boiler,
make connections to
the hot water coil and
provide valves to
backflush the coil.
2. The coil is made of thin,
finned copper tubing and
should be handled carefully in the event of
removing, cleaning or installing.
⚠IMPORTANT
Do not install a domestic hot water coil without
a thermostatic mixing valve. Install the mixing
valve at the hot water outlet. Adjust and
maintain the mixing valve according to the
manufacturer’s instructions.
GENERAL PIPING DIAGRAMS
Figure 3 –Hot Water Piping
Tankless Coil

Page | 16
Figure 4 –Hot Water Piping with Domestic Hot Water
Figure 5 –Hot Water Piping, Multiple Zones

Page | 17
VENTILATION & CHIMNEY CONNECTIONS
1. Vent system installation must be in
accordance with National Fuel Gas Code, ANSI
Z223.1/NFPA 31/NFPA 54 latest revision and
applicable provisions of local building codes.
2. Direct vent and chimney vent are the two
applications that are recommended and
approved by Dynatherm™ when installed
according to the proper installation
instructions.
a. See Figures 6 & 7 below for basic
diagrams.
3. A power vent is an optional feature that is
only approved when installed per the power
vent installation instructions.
4. A draft regulator should NOT be installed with
the boiler.
5. The Dynatherm™ boiler is a positive pressure
boiler in which the flue gases are being forced
through the boiler instead of being drawn out
by natural drafts.
6. If venting through the chimney, make sure
the chimney is clean of fly ash or carbon.
7. If the chimney is in poor condition, unlined or
unprotected from precipitation, condensation
will flow down the inside of the chimney and
in some cases, the outside of the chimney.
a. This can be eliminated with the
installation of an H-stack cap or other
stack-capping devices similar to the
Wigwam cap.
8. Since the size of the flue connection is 5"
round, breaching to the chimney or wall
should be a 5" pipe.
⚠CAUTION
The 5” flue cannot be reduced. Reducing the
flue size can cause the boiler to build up
condensation, which could result in property
damage or serious injury and void the warranty.
9. The flue pipe should be as short as possible
and not exceed three 90° elbows in the
chimney or wall breaching.
10. The flue side not being used should be
capped off with a stainless steel flue cap.
11. Because this is a forced draft system, all joints
in the flue pipe must be made gas tight by
sealing with thermosetting pressure sensitive
tape.
12. Do not install a fireplace duct on the same
flue section as the boiler.
Figure 6 –Direct Vent Figure 7 –Chimney Vent

Page | 18
FUEL SUPPLY
1. Fuel gas piping must be in accordance with
National Fuel Gas Code, ANSI Z223.1/NFPA
31/NFPA 54 latest revision and applicable
provisions of local building codes.
2. The Dynatherm™ boiler is listed by the
Underwriters Laboratories to burn the
following gases:
Number 2 fuel oil.
Propane, in accordance with national
regulations, with a content of elementary
Sulphur less than 1.5 ppm and volatile
Sulphur less than 50 ppm.
Natural gas from the public gas supply, in
accordance with national regulations,
with a total Sulphur content less than
15ppm.
NOTICE
Since fuel grades marketed by different
distributors may vary, it is advantageous for you
to be familiar with the quality of fuels available
in your area.
3. Before installing and connecting any fuel
lines, turn off the main fuel supply. If there is
no shutoff valve, install a valve between the
fuel tank and fuel pump in accordance with
local codes.
4. Install a ground joint union for servicing, if
required.
5. Connect the suction line from the fuel tank to
the pump using an unbroken length of copper
tubing and flare type fittings as required by
the burner manufacturer.
6. In cases where there is an underground or
remote fuel tank, it is recommended to use a
Suntec Model A1VD-7741 Pump and 1/6 HP
motor to maintain proper fuel delivery.
7. If using No. 2 fuel oil, an external,
appropriately listed and certified fuel filter
must be placed in the fuel line between the
fuel tank and the burner pump.
A Gar-Ber fuel oil filter is recommended.
8. Ensure that all air is out of the fuel lines.
Whenever any line in the system is opened,
air must be bled from the high points of the
system. The boiler should always be double
checked for air.
9. Turn on the main fuel supply/shutoff valve
and check for any leaks using an approved
combustible gas detector, soap and water, or
similar nonflammable solution.
⚠DANGER
Do not use matches, candles, flames or any
ignition source to check for leaks.
ELECTRICAL WIRING
1. All electrical equipment and wiring must be
installed in accordance with the National
Electric Code, ANSI/NFPA-70 latest revision
and applicable provisions of the local building
codes.
2. Wiring is to be done inside BX cable or
conduit.
3. All connections must be soldered or approved
connectors. The minimum wire gauge
conductor size should be #14.
4. Since the Dynatherm™ boiler is supported by
numerous burners and controls, please refer
to the wiring diagrams in those manuals for
proper wiring.
INITIAL BURNER SETUP & START-UP
1. Refer to the burner installation manual
provided with your burner for proper setup &
start-up procedures.
2. Use the proper instruments to adjust the
burner settings to achieve 11% - 13% CO2
readings and a smoke reading of zero.
NOTICE
Variations in flue gas, smoke, CO2and
temperature readings may be experienced
when the burner cover is put in place.
Therefore, the burner cover must be in place
when making the final combustion instrument
readings to ensure proper test results.

Page | 19
BOILER MAINTENANCE
INSPECTION
A Dynatherm™ boiler is operating properly when
there is no smoke. A zero smoke reading on the
Bacharach scale is an acceptable indication. The
CO2level should be between 11% and 13%. If
either of these two conditions is not obtainable,
an inspection of the equipment and the functional
parameters is indicated. Only a qualified
Dynatherm™ technician should perform the
inspection and maintenance on this boiler.
⚠IMPORTANT
Replace the front head and end head rope
gaskets during every maintenance and cleaning.
1. Examine the gaskets on the front head, end
head, inspection plate and burner gasket.
Small soot deposits forming on the tube sheet
may be an indication of a leak.
a. If a leak is found, tighten the bolts or
replace the gaskets as necessary.
2. Check the domestic hot water coil plate and
gasket for any water leaks.
a. If a leak is found, tighten the bolts or
replace the gasket.
3. Inspect the 13 fire tube expansion joints at
both tube sheets for any signs of water leaks.
Water buildup in the front head, end head
and third pass chamber may be an indication
of a leak.
a. If a leak is found, contact Dynatherm™ for
the proper procedure to repair or replace
the leaking tube(s). Do not attempt to
repair or replace the leaking tube(s)
unless you’ve been properly trained by a
Dynatherm™ employee on tube rolling.
4. Verify the boiler water temperature and
pressure on the temperature/pressure gauge
(tridicator) are at the recommended settings.
5. If the boiler water is hot enough but the
domestic hot water is still not satisfactory, the
system could have some oil film which may
have insulated the fins on the hot water coil.
a. This can be corrected by flushing acid
through the coil to remove the buildup.
DISASSEMBLY
1) Remove the four (4) brass nuts on the end
head.
2) Lower the end head to the horizontal position
by the hinge, being careful not to let the scroll
drop.
3) Mark an area on top of the scroll with a black
marker for reassembly and then remove the
scroll. Take note of which side of the scroll
goes against tube sheet.
4) Remove the hinge bolt. The end head should
now be free from the boiler.
5) Disconnect the electrical wiring from the
burner.
6) Disconnect the fuel line(s) from the burner.
7) Remove the four (4) brass nuts from the front
head assembly. Carefully remove the
assembly from the boiler in order to avoid
damaging the gaskets and air tube insulator.
REASSEMBLY
1) Replace the rope gaskets on the front head
and end head. Use a high temperature spray
adhesive to secure the rope in place.
2) Place the front head in position.
3) Tighten the four (4) brass nuts evenly and
across corners to further assure a tight seal.
4) Mount the burner and reconnect the
electrical wiring and fuel line(s).
5) Make sure the combustion tube liner is fully
seated against air tube insulator.
6) Mount the scroll on the fire tubes. Make sure
the black mark you made with the marker is
on the top and the scroll is facing the correct
way against the tube sheet.
7) Replace the hinge bolt through end head
casting and carefully close the end head. Use
care so you do not disturb the scroll.
8) Tighten the four (4) brass nuts evenly and
across corners until the gasket is tight.
9) Bleed the fuel line(s) to the pump. The boiler
is now ready for firing.
10) Proceed with the Initial Burner Setup & Start-
Up procedure, record CO2levels, smoke
readings and air adjustments for the
homeowner.

Page | 20
CLEANING PROCEDURE
1) Remove the four (4) brass nuts at the end
head and hinge the head down to expose the
tubes and scroll. Inspect the scroll for cracks
and other damage, and replace the scroll if
necessary.
2) Clean the fire tubes with a shop vacuum
and/or tube brush. If there is any carbon
inside the combustion tube, clean it out.
3) Inspect the end head refractory insert and
replace if necessary.
4) Clean the inspection sight glass and replace if
necessary.
5) Replace the end head rope gasket.
6) Remove the inspection plate at the front head
(burner end) and clean the inside thoroughly
with a vacuum.
7) Remove the flue cap and clean inside the
belly pan. Replace the flue cap once finished.
8) Inspect the exhaust pipe and tape, and clean
or repair if necessary.
9) Clean or replace the burner nozzle per the
burner manual, making sure to use the proper
size and angle.
10) If using No. 2 fuel oil, replace the oil filter
element.
11) If there is any indication that any other
gaskets are leaking, replace those gaskets
immediately.
12) Reinstall the cleanout cover, scroll, end head
and stack connections. Make sure that all
vent connections are taped and secured with
screws.
⚠WARNING
Do not omit the scroll. The scroll is important to
assure the efficient operation of the boiler.
13) Fire up the boiler and double check for any
leaks in gaskets or stack joints. Make sure the
CO2, air control setting and smoke test are to
the recommended levels. Refer to the Initial
Burner Setup & Start-Up section of this
manual.