Crown Boiler 24-03, 24-04, 24-09, 24-10, 24-05 User Manual
...
D E S I G N E D T O L E A D
Series 24
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com
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
• 24-06
• 24-07
• 24-08
• 24-09
• 24-10
WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas supplier.
This boiler requires a special venting system. Read these
instructions carefully before installing.
• 24-11
• 24-12
1
2
IMPORTANT INFORMATION - READ CAREFULLY
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DANGER
Indicates an imminently haz ardous situation
which, if not avoided, will result in death,
serious injury or substantial property
damage.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate
or minor injury or property damage.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property
damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are
important but not related to personal injury
hazards.
3
WARNING
Imp roper ins tallation, adju stment, alteration, service or main tenan ce can cause p roperty
da mage, personal injury or loss of life. Failu re to follow a ll in structions in th e proper orde r
ca n cause personal in jury or death. R ead and u n d erstand all instructions, including all
those con tained in compon e nt manufa cturers manuals which are pro vide d w ith the
ap p liance before installing, starting-up, o perating, maintaining or servicing this appliance.
Keep this man u al an d literature in legib le con d itio n a nd poste d near ap p liance for referenc e
by o w ner and serv ice technician.
Th is boiler requires regular main tenan c e and servic e to operate safe ly. Follo w the
instructions contain e d in this manual. Ins tallation, mainte nance, and servic e must be
pe rformed only by an experienced, skilled and knowledgeable installer o r servic e agency.
All h e ating systems should be designed by competent co n tra ctors and only persons
kn o w ledgeable in the layout and insta llation of hydro n ic hea ting systems should a ttempt
installation of any b oiler. It is th e respo n sibility of the installing contractor to see that all
co n trols a re correctly in stalled and are opera ting prop e rly w hen the installation is
co mplete d . Installatio n is not comp lete unless a pressure relief va lve is installed into the
sp ecified ta p ping located at the rear of applian c e - See Section III of this manual for details.
Th is boiler is suita b le for insta llation on combustible floorin g . Do not install b o iler o n
ca rpetin g . Do not operate on flo o rs where h eat affecte d material is b elow.
Do not tamper w ith or alter the boiler or controls. Retain your co n tractor or a competen t
se rviceman to as sure that the unit is properly adjusted and main tained.
Clean boiler at le ast onc e a year - preferably at the start of the heating season to remove
so o t and sc ale. The inside of c ombustion chamb er should also be cleaned and inspected
at th e same time.
Have B u rner and C o ntrols c hecked at le ast once a y ear or as ma y be necess itate d .
Do not operate unit w ith jumpered or absent controls o r safety devices.
Do not operate unit if any control, sw itch, componen t, or device has bee n subject to w a ter.
Return w ate r cannot be low e r th an 135°F for prolonged p e riods of time. Op eratio n under
these co n d itio n s w ill result in susta ined c ondensing w ithin the combustion ch a mber and
po tentia lly reduce boile r longevity.
In addition, th e return water can n o t be introduced into the boiler if it is mo re than 40°F le ss
than the id le boiler tempe rature. Continued operation under these conditions may res u lt in
prema ture boiler failure thro u gh thermal shock .
Exa mple
: A b oiler that has been idle fo r some time since th e la st heat demand cycle ma y
ha ve it's boiler water temperatu re reduced to 150°F. The retu rn te mperatu re from the nex t
zone activa tion cannot be less th a n 110°F.
If the abo v e conditions exist, an R TC system must b e installe d to protect th e boiler from
su stained con d ensin g o peration and th e rmal sh o ck.
DANGER
DO NOT store o r use gaso line or o ther flammable vapors or liq u ids in th e vicinity o f this or a n y
other appliance.
4
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NOTICE
All Series 24 cast iron boilers are designed, built, marked and tested in accordance with the
ASME Boiler and Pressure Vessel Code
, Section IV
, Heating Boilers
. An ASME Data Label is
factory applied to each Series 24 jacket, which indicates the boiler Maximum Allowable Working
Pressure (MAWP). Each cast iron section is permanently marked with the MAWP listed on the
boiler's ASME Data Label. Those values for the Series 24 are as follows:
MAWP, Steam - 1
5 psi
M
AWP, Water (USA) - 80 psi
M
AWP, Water (Canada) - 45 psi
I
t is common and acceptable practice to install these boilers in lower pressure systems, below
the boiler MAWP. Therefore, Crown offers safety relief valves set at or below the MAWP of the
boiler. See page 9 for standard safety relief valve set pressures.
5
TABLE OF CONTENTS
SECTION I - GENERAL INFORMATION
Dimensional Information ............................................................................................................................................... 8
Ratings/Data .................................................................................................................................................................. 9
Locating the Unit . ........................................................................................................................................................ 10
Air Supply/Venting ....................................................................................................................................................... 11
SECTION II - CAST IRON BLOCK ASSEMBLY
Assembly of Sections, Manual Draw-up ..................................................................................................................... 13
Assembly of Sections, Hydraulic Draw-up ................................................................................................................. 16
Hydrostatic Test ........................................................................................................................................................... 18
SECTION III - INSTALLATION INSTRUCTIONS
Knockdown
Canopy ......................................................................................................................................................................... 19
Flue Cover Plates ......................................................................................................................................................... 22
Rear Observation Port Cover ........................................................................................................................................ 23
Inspect All Boiler Seals ................................................................................................................................................ 23
Jacket Assembly .......................................................................................................................................................... 23
Burner Mounting Plate / Burner Adapter Plate ........................................................................................................... 25
Steam Trim .................................................................................................................................................................. 26
Water Trim . .................................................................................................................................................................. 30
Burner Installation ....................................................................................................................................................... 32
Common Installation Requirements
Boiler Piping - Heating Applications .......................................................................................................................... 32
Boiler Piping - Domestic Hot Water (DHW) Applications .......................................................................................... 33
Tankless Heater Piping ................................................................................................................................................ 41
Electric Wiring ..............................................................................................................................................................43
Return Temperature Control (RTC) and Components .................................................................................................. 43
SECTION IV - OPERATING INSTRUCTIONS
Filling System ............................................................................................................................................................... 47
Adjusting Controls ....................................................................................................................................................... 47
Adjusting Burner ......................................................................................................................................................... 48
Return Temperature Control; Initial Set-Up and Operation .........................................................................................48
Diverting Valve Actuator .............................................................................................................................................. 50
Boiler Operating Aquastat ............................................................................................................................................ 50
Boiler High Limit Aquastat .......................................................................................................................................... 50
Boiler Modulating Control ........................................................................................................................................... 50
Test Controls ................................................................................................................................................................ 50
Initial Cleaning, Steam Boilers .................................................................................................................................... 51
Initial Cleaning, Water Boilers ....................................................................................................................................52
Frequent Water Addition ..............................................................................................................................................53
Oxygen Corrosion ........................................................................................................................................................53
SECTION V - SERVICE INSTRUCTIONS
Cleaning Boiler Heating Surfaces ............................................................................................................................... 54
Maintenance of Low Water Cutoff Devices ................................................................................................................55
Checking Burner & Controls ........................................................................................................................................ 56
Lubrication ...................................................................................................................................................................56
General Maintenance Considerations ........................................................................................................................... 56
Attention to Boiler While Not in Operation ................................................................................................................. 56
6
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 .......................................................................................................................................................... 60
Bare Boiler Assembly ................................................................................................................................................... 62
Steam/Water Trim ......................................................................................................................................................... 65
RTC Related Components ............................................................................................................................................ 66
SECTION VIII - APPENDIX
A. Application Drawings - Mechanical and Electrical
A1. 3-way RTC in Primary/Secondary – Heating Only/No DHW; with/without Outdoor reset
A2. 3-way RTC in Primary/Secondary – Heating/DHW with/without priority using Tankless coils and Outdoor reset.
A3. 3-way RTC in Primary/Secondary – Heating/DHW with/without priority using Indirect Water Heater and
Outdoor reset.
A4. 3-way RTC in Primary/Secondary –Indirect Water Heater as load on primary loop without Outdoor reset.
A5. 3-way Multiple Boiler RTC in Primary/Secondary – Indirect Water Heater (or other heat exchanger) as Load on
Primary Loop using Sequencer and Outdoor Reset.
A6. Tankless Application Only with boiler circulation loop. No building heating load.
A7. Indirect Water Heater Only with boiler circulation loop. No building heating load.
B. Boiler Circulator and Diverting Valve Selection Charts
B1. S24, 20 and 40 ∆Τ − Taco
B2. S24, 20 and 40 ∆Τ − Grundfos
B3. S24, 20 and 40 ∆Τ − Bell and Gossett
B4. S24, 20 and 40 ∆Τ - Armstrong
C. Valve and Actuator Mounting Instructions
7
Section I - General Information
FIGURE 1: Dimensional Information
8
TABLE I
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30-42
2.01 243 1
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161 7
40-42
1.41 174 1
741 353 014 01.4 495 6.84 3.45 8.4 83. 0.35 0.57 1181 5991 7
50-42
9.81 436 3891 674 155 05.5 297 0.36 5.17 4.6 1
3. 5.16 0.48 4812 2732 8
60-42
8.32 797 2942 895 396 09.6 099 5.77 8.88 9.7 8
3. 0.07 0.39 7552 9472 8
70-42
0.82 739 9292 307 518 01.8 4711 9.19 0.601 5.9 6
3. 5.87 0.201 0392 6213 8
80-42
5.23 7801 6933 518 549 04.9 8531 3
.601 3.321 0.11 53. 0.78 0.111 3033 3053 01
90-42
3.93 6131 6414 599 8411 04.11 1461 7.021 5
.041 6.21 53. 5.59 0.021 6763 0883 01
01-42
0.54 5051 8874 9411 9031 00.31 7681 1
.531 8.751 2.41 04. 0.401 0.921 8404 7524 01
11-42
5.05 0961 9245 3031 0741 06.41 3902 5
.941 0.571 7.51 54. 5.211 0.831 1244 4364 21
21-42
3.55 2581 3895 6341 0161 00.61 0232 0
.461 3.291 3.71 94. 0.121 0.741 4974 1105 21
BOILER RATINGS/DATA
(1) Trim Suffix: S = Steam Boiler, W = Water Boiler
Fuel Suffix: N = Natural Gas, P = LP Gas, O = Oil
(2) I=B=R net ratings shown are based on piping and pick-up allowances which vary from 1.333 to 1.289 for steam and
1.15 for water
intermittent system operation, extensive piping systems, etc. The I=B=R burner capacity in GPH is based on oil having a
heat value of 140,000 BTU per gallon.
(3)
(refer to Figure 1), add 0.7 cu. ft. to volume listed above.
(4)
fl
Firebox volume does not include added volume of 8” extended burner mounting plate (BMP). If 8” BMP is specified
Boiler ratings are based on 12.5% CO2 (oil) and 9.7% CO2 (natural gas), + .10” (inches) water column pressure at boiler
ue outlet. Ratings shown above apply at altitudes up to 1000 feet on oil and 2000 feet on gas.
. Consult manufacturer for installations having unusual piping and pick-up requirements, such as
For altitudes above those indicated, the ratings should be reduced at the rate of 4% for each 1000 feet above sea level.
Maximum Allowable W
Standard Safety (Relief) Valve Set Pressure: Steam Boiler - 15 PSI, Water Boiler - 30 PSI
orking Pressure: Steam Boiler - 15 PSI, Water Boiler - 50 PSI
9
SECTION I - GENERAL INFORMATION (CONTINUED)
Flue
Outlet
Size
Top
Flue
Outlet
Rear Flue Outlet
Combustible
Surfaces
Non-Combustible
Surfaces
7" D ia.
18"
37" 22"
8" D ia. 38" 23"
10" Dia. 40" 25"
12" Dia. 43" 28"
NOTICE
Reco mme n ded clearan c e for serv ice may be
reduced to minimum cle arance to
co mbustib le material. How ever, in creas ed
se rvice and main tenanc e difficulty w ill
result.
WARNING
Boiler is suitab le for installatio n o n
co mbustib le flo or. D o n o t install boiler
on c arpetin g.
Floor construction s h ould have
ad equate load bearin g charac teristics
to bear the weight of the boiler filled
with water (see Table 1). A boiler
foundatio n similar to the one shown in
Figure 2 is recommen d ed if the b o iler
room floor is w eak or uneven or if a
water co n d itio n e xis ts.
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A. INSPECT SHIPMENT carefully for any signs of
damage.
1. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of crated boiler to the carrier in good
condition.
2. ANY CLAIMS for damage or shortage in shipment
must be filed immediately against the carrier by the
consignee. No claims for variances from, or shortage in orders, will be allowed by the manufacturer
unless presented within sixty (60) days after the
receipt of goods.
3. Make sure that appropriate items on the Master Parts
List (pg 59) are all on hand.
B. LOCATE THE UNIT
1. RECOMMENDED SERVICE CLEARANCE
- Locate the unit in the boiler room so as to
provide ease of venting and adequate clearance
for maintenance, serviceability, and installation of
piping. Refer to Figure 1 for boiler dimensional
data.
FRONT — Provide 43” service clearance for
removal, maintenance, and servicing of burner and
controls.
REAR — Provide a minimum clearance from the
boiler jacket for access to flame observation port,
rear flue damper and vent piping, relief valve, and
boiler return piping. See Table III.
LEFT SIDE — Provide a minimum clearance from
the boiler jacket of 26” for cleaning of flueways and
installation and removal of tankless heater(s).
RIGHT SIDE — Provide a minimum clearance from
the boiler jacket of 12”.
T
OP — Provide a minimum clearance from the
boiler jacket of 24”
2. FOR MINIMUM CLEARANCES to combustible
materials, See Table II.
3. PROVIDE ADEQUATE FOUNDATION for the
unit. Refer to Figure 2.
Table II: Minimum Clearances To Combustible
Materials (Inches)
Boilers with Top Flue Outlet
Boilers with Rear Flue Outlet
Table III: Recommended Rear Service Clearance
10
Figure 2: Boiler Foundation
WARNING
Fa ilure to supply adequate air to the boile r
will re sult in u nsafe b o iler o p eratio n .
C. PROVIDE AIR SUPPLY AND VENTILATION to
accommodate proper combustion.
For commercial and industrial equipment, permanent
facilities for supplying an ample amount of outside air
shall be provided in accordance with the following.
For boiler rooms adjacent to outside walls, and where
combustion air is provided by natural ventilation from
the outside, there shall be a permanent air supply inlet
having a total free area of not less than 1 sq. inch per
4,000 Btu per hr. (35 sq. inch per gallon per hour)
(5.5 cm2 per kw.) of total input rating of the burner or
burners and in no case less than 35 sq. inch (0.425m2).
For boiler rooms not adjacent to outside walls, the
combustion air shall be supplied in a manner acceptable
to the authority having jurisdiction.
1. In the absence of local requirements, the confined
space shall be provided with two permanent
openings, one in or near the top of the room and one
near the bottom. The openings shall communicate
by means of ducts, with the outdoors or to such
spaces (crawl or attic) that communicate with the
outdoors.
a. Where communicating by means of vertical
ducts, each opening shall have a free area of not
less than 1 sq. inch per 4,000 Btuh (35 sq. inch
per gph) (5.5 cm2 per kw) of total input rating of
all appliances in the enclosure.
b. If horizontal ducts are used, each opening shall
have a free area of not less than 1 sq. inch
per 2,000 Btuh (70 sq. inch per gph.) (11 cm
per kw) of total input of all appliances in the
enclosure.
2
D. CHIMNEY OR VENT
The Series 24 boiler is designed for forced draft firing
and may be used with a conventional natural draft
stack (15’ minimum height) or a stub vent, sometimes
called a diesel stack (see Figure 3a). See Table I for
the proper vent outlet size. For low silhouette vent
terminations, see Figure 3b. Draft controls are not
normally required, although they may be used on
installations where a natural draft stack is used or on
multiple boiler installations with a common stack. The
boiler is provided with a breeching damper, which
should be adjusted to maintain a positive pressure of
0.1” W.C. in the vent connector box during burner high
fire operation (see breeching pressure sensing port in
Figure 1).
Figure 3a: Typical Arrangement for Stub Vent
11
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If the venting system is designed for positive or forced
draft venting, the boiler, vent connector and stack will
operate under positive pressure. Gas tight vent systems
designed for pressure systems must be used to prevent
flue by-product leakage. The vent height is usually
limited to prevent negative draft, typically three (3)
feet above the roof line (see Figure 3a). The damper
shall be adjusted to maintain a positive pressure of 0.1”
W.C. in the vent connector box during burner high fire
operation (see breeching pressure sensing port in Figure
1).
If the venting system is designed for negative pressure
(natural draft), the boiler still operates with positive
pressure in the chamber and up to the fixed damper on
the flue collar. However, if the venting system is larger
than what is required, the stack will provide a surplus
draft (or negative pressure) that may require the use of
a barometric damper to maintain the positive 0.1” W.C.
pressure at the flue outlet. Multiple forced draft boiler
stacks should always be designed as negative to ensure
the products of combustion do not exit a boiler that is
not firing.
FIGURE 3b: VENTS — FAULTS & SUGGESTIONS
TYPICAL VENTS THAT ARE USED ON FORCED DRAFT BOILERS, ON LOW SILHOUETTE BUILDINGS
A
RAIN CAP
RIGHT
D
WRONG
VENT SIZING - Area must be the same as or greater than the boiler breeching (Smoke Outlet). A barometric damper may be required on
installations with a high draft condition.
1. If improper vent is suspected, remove pipe at breeching and operate boiler. This will determine if excessive down draft,
blocked or restricted flue, etc. is causing the problem.
2. If using type shown in A above, be sure cap is raised sufficiently above main pipe to allow flue gases to vent unimpeded.
3. A popular type cap is shown in B.
4. The tee is frequently used as shown in C.
5. D and E should not be used due to possible fl
B
“A” CAP
RIGHT
E
WRONG
FAULTY BOILER BURNER OPERATION
uctuations in back pressure.
C
TEE TYPE
RIGHT
90°
ELBOW
UP or DOWN
12
CAUTION
Boiler sections must be draw n -up on
pe rfectly level surface or improper
as sembly may res ult.
CAU TION
When assembling sec tions without
hy draulic draw-u p equip ment, nev er
as semble mo re than one sectio n at a time.
SECTION II - CAST IRON BLOCK ASSEMBLY
A. FIELD ASSEMBLED SECTIONS — If the boiler
was ordered to be field assembled, follow the assembly
procedure outlined on the following pages.
1. ASSEMBLY OF SECTIONS (MANUAL DRAWUP)
These sections are designed to be drawn together,
one section at a time, using the 9¾” long draw-up
rods (provided) and ordinary hand tools.
Tools required:
(1) ¾” Drive Ratchet
(1) 1-1/16” Socket
(1) 1-1/16” Combination or Open End Wrench
(1) Container of grease, oil or other appropriate
lubricant.
ENSURE THAT THE ADHESIVE DOES
NOT COME IN CONTACT WITH THE
NIPPLES OR NIPPLE PORTS.
e. Clean nipples and nipple ports thoroughly with
a de-greasing solvent. Use the Loctite #592
supplied to lubricate the nipples and nipple
ports. Apply the lubricant to the nipples and
nipple ports, then use a brush to disperse it
evenly around the nipples and the nipple ports.
Use approximately 25 ml of Loctite #592 per
flueway [(1) 7” and (2) 3” nipples and their (6)
corresponding nipple ports].
f. Drive nipples squarely into section using
block of wood and hammer, or preferably,
an aluminum head hammer. (Crown offers a
Polyethylene Block for setting the nipples, part
number 330010). Place block over entire nipple
edge and hit the wood with the hammer.
a. Place the rear section in its approximate final
position, as outlined in Section I, and support it
with a suitable prop and wedges. See Figure 5.
b. On size 24-03 only— Open target wall carton,
apply Silastic to back of target wall and secure
target wall to rear section.
c. Clean the groove in the ground joint along the
edge of the section with the wire brush.
d. Open the Boiler Assembly Carton(s) and remove
the bottle of adhesive. Using the dauber supplied
in the bottle, apply the adhesive to the groove.
Be sure to use enough adhesive to sufficiently
coat the entire groove surface. If so desired,
a multi-purpose spray adhesive (supplied by
others) may be used instead. HOWEVER,
GREAT CARE MUST BE TAKEN TO
Figure 5: Positioning of Back Section
13
WARNING
Nipples mus t be drive n in eve nly a nd to
the pro per depth to a ssure tight joints.
Most n ipple leaks are caused b y tilted
or cocked nipples.
DO NOT use steel/iron head hammer to
drive nip p les w ithout usin g a w ood
block. Nip p le damage may result.
g. A special nipple setting gauge is provided for
WARNING
Sec tions mu s t be draw n -up tig h t
immediate ly a fter properly ap p lying
se ala n t for best re sults. Although
se ctions may be join e d w ithin tw o (2)
ho u rs of applyin g sealant, humidity and
temp erature a ffect c ure time. If a "thick
sk in" has b e en formed o n the sea lant
be ad, remove an d re-apply sealant.
Sea lant mus t be properly applied to
ALL grooves. Failure to pro perly seal
the boile r join ts will resu lt in
co mbustio n g as le aks th rough the jo int.
DO NOT operate boile r with
co mbustio n g as le aks.
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
touching finished face of section, when nipple is
properly driven. See Figure 6.
h. Remove a 96” length of fiberglass rope from the
assembly carton. Starting with the area around
the upper 7” nipple port, firmly press the rope
into the groove, so that the adhesive holds it in
place. (If more than 25 minutes have passed
since the adhesive was applied, it may be
necessary to reapply.) Continue to affix the
rope to the groove in this fashion around the
perimeter of the section. Make sure that the rope
does not droop or hang outside of the groove.
When the end of the groove is reached, cut off
the excess rope. Push the length of excess rope
into the groove at the top corner of the section
face (opposite of the 7” nipple port.) Cut off and
discard any remaining rope after groove is filled.
See Figure 7.
Figure 6: Nipple Gauge
Figure 7: Affixing the Fiberglass Rope
14
NOTICE
Th e sections must b e assemb led according
to th e arrangeme n t shown to ensure p roper
op e ratio n , proper as sembly of canopy,
jacke t and alignment of p iping and tankless
he aters w ith ja cket k n ockouts. Start w ith
the back section and w o rk tow a rds the
fro n t.
CAUTION
To avoid damage to the draw-u p rod
thre ads w h ile dra w ing up sections , apply
oil or other lubrican t to tie rod threa ds
while assemb ling sectio ns to prevent
stripping of threads on ro d and to make
as sembling easier.
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: Series 24 Section Arrangement
i. From the “Section Arrangement” chart, select
the next section according to the “Identification
Code” at the top of the chart. See Figure 8. Use
a wire brush to clean the groove in the face of
the next section. Then, using a cartridge of RTV
6500 or RTV 736 sealant in a caulking gun, fill
the groove in this section with silastic sealant.
Touch-up any missed spots before draw-up.
T
ouch-up after draw-up has no value.
j. Clean and lubricate nipple ports on next section
to be assembled and place on nipples previously
installed in rear section. To facilitate assembly,
it is advisable to enter the upper nipple first in
its port. Then enter the lower nipples in their
respective ports. If necessary, place a lifting bar
15
(crowbar) under the center of the section and lift
the nipple port onto the upper nipple.
k. Drive section in place with a heavy block of
wood, striking blows as squarely as possible over
nipple port.
l. The lar
m. DRAW UP SECTION SLOWLY AND
ge draw-up rod lugs with dual holes
are cast in the four (4) corners of each casting.
Starting with the upper holes, install four
(4) 5/8” x 9¾” long draw-up rods along with
washers and nuts (see Figure 9).
EVENLY using an alternating pattern starting
with the upper right lug and proceeding to the
lower left , lower right and finishing with upper
left lug.
WARNING
Do not over torq u e draw up nuts after grind
su rfaces me et.
Figure 9: Draw-Up Rods (Alternating Pattern -
GNINRAW
LLAotdeilppaylreporpebtsumtnalaeS
reliobehtlaesylreporpoteruliaF.sevoorg
skaelsagnoitsubmocnitluserlliwstnioj
reliobetarepoTONOD.tniojothguorht
tnalaesehT.skaelsagnoitsubmochtiw
sinoitceshcaeerofebdeilppaebdluohs
.ylbmessaehtnodecalp
Manual Draw-up)
When you start, grind surfaces between
adjoining sections should be approximately
3/8” apart. Use three (3) or four (4) passes at
tightening the four (4) draw-up rods a little at
a time so that sections are pulled up evenly.
During the last pass, pay close attention to the
silastic sealant as it squeezes when the sections
come in close contact. The silastic sealant will
continue to squeeze out wafer thin until the
sections are connected metal to metal. While
tightening the nuts, close attention should be
given to the connection area to determine that
the silastic has stopped squeezing out from
between the sections. This will give assurance
that the sections are assembled metal to metal. If
the silastic has stopped squeezing out from the
connection and the sections still do not appear
to be drawn metal to metal, measure any gaps
between the sections with a feeler gauge. A
maximum gap of .025” is acceptable. Gaps
should be measured at the outer edge of the
connection. DO NOT PUNCTURE THE
GASKET CREATED BY THE FIBERGLASS
ROPE AND SILASTIC
SEALANT WITH THE FEELER GAUGE.
KEEP NIPPLES ALIGNED WITH NIPPLE
PORTS. If necessary, tap edge of nipples lightly
with a blunt tool or rod to keep nipples from
cocking while sections are being drawn-up. DO
NOT DRAW UP SECTION WHEN NIPPLES
ARE COCKED. If the torque required becomes
excessive, periodically place a heavy block of
wood over
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 as the boiler operates with a
positive pressure in the firebox and products of
combustion will escape between sections unless
the sections are properly sealed. The sealant
should be applied before each section is placed
on the assembly.
o. If a joint springs apart it must be redrawn tight
within four (4) hours of the time of application of
Silastic to that joint.
2. ASSEMBL
UP)
The entire boiler assembly may be drawn up at one
time using hydraulic draw-up equipment providing
the operation is completed within four (4) hours after
application of the sealant.
a. Repeat steps 1a through 1k under “Field
Assembled Sections (Manual Draw-Up).”
b. Continue driving sections in place (in their
respective order) until all sections are in the
assembly. Ground surfaces between adjoining
sections should be spaced 1/4” to 3/8” apart.
Spacing of more than 3/8” will limit number of
sections that can be drawn up in one unit and
could indicate cocked nipples.
On long boiler assemblies, it may be necessary to
draw-up a partial block if the entire boiler is not
ready to be drawn-up tight within four (4) hours
of the first application of Silastic. If the block
assembly time extends overnight, the partial block
completed must be drawn-up tight before leaving
the boiler overnight. If a joint springs out, it must
be redrawn tight within four (4) hours of first
application of Silastic to the joint.
16
c. Insert the three (3) ¾” draw-up rods (and
couplings, if appropriate) through the tapped holes
in the rear section extending them through the
each nipple port and strike as squarely
Y OF SECTIONS (HYDRAULIC DRAW-
CAU TION
Do not apply pres sure directly on thread e d
tappings on front and rea r sectio ns w ith
draw-up ch a nnels during assembly
procedures.
Rods should be approximately centered in
op e nings s o that rods a n d couplings (when
us ed) do not drag o n p ipe thread in end
se ction tappin g s.
WARNING
READ THE STATEMENTS BELOW BEFORE
ATTEMPTING TO USE HYDRAULIC EQUIPMENT.
*
*
*
*
Re
lease p ressu re in ram pumps b e fore
attemptin g to re move clamp s .
Do not sta nd in line w ith draw -up ro d s at
either en d w hen hydraulic p ressure is
be ing ap p lied. As a safe ty measure,
en d s of draw-up rods should be covered
while sections are bein g drawn in case
rods should snap while under te n sio n .
Do not operate ram ag a inst dra w -up
co u pling.
Do not operate pump after ram has
reached s tro ke limit.
tapped holes in the front section. Be sure to
screw draw-up rods into couplings far enough to
prevent stripping threads.
d. Place a 3” x 12” lg. steel channel on each end of
the upper draw-up rod and a 3” x 8½” lg. steel
channel on each end of the lower draw-up rods.
Refer to Figures 10 and 11 for proper placement
of channel block during assembly procedures.
Install nuts and washers on one end of the drawup rods and the hydraulic rams, washers and
draw-up rod clamps on the other. See Figure 13.
g. After all sections have been drawn up, but before
removing the hydraulic rams and draw-up rods,
the 9¾” long tie rods must be installed.
The large draw-up rod lugs with dual holes
are cast in the four (4) corners of each casting.
Starting with the upper holes in the back section,
install four (4) 5/8” x 9¾” long tie rods along
with washers and nuts. Continue installing the
tie rods alternating from the upper to lower set
of holes in draw-up lugs until front section is
secured. Be certain that all sections are drawn
up IRON TO IRON at all three nipple ports.
h. Excess length of draw-up rods must not extend
beyond front and rear section. To ensure proper
fit of jacket, adjust accordingly. Tighten all tie
rod nuts until finger tight. Then tighten them
an additional ½ turn with a wrench to prevent
section damage to thermal expansion.
e. Draw-Up Sections
Use hydraulic rams to draw up sections by
applying pressure alternately on the draw-up
rods. When rams reach stroke limit, release
pressure in ram pumps and then move clamps to
new position.
f. Continue to draw-up until all sections make
contact at the ground joints.
Figure 10: Front and Rear Section Channel
Block Positions (Hydraulic Draw-up)
Figure 11: Center Section Channel Block Position
(Partial Block Draw-Up)
17
Figure 12: Hydraulic Draw-Up of Sections
CAU TION
DO NOT install gauge until after hydro s tatic
testing the boiler. Gauge failure may result.
WARNING
Fa ilure to pro p erly hydrotes t all b o ilers at
the correct pres sure may re sult in section
as sembly failure in o p eratio n .
B. HYDROSTATIC TEST — After the boiler sections
have been assembled, it is essential that the boiler be
hydrostatically tested before the canopy, flue cover
plates, jacket, or piping is installed.
1. Tankless Heater Installation
If boiler is ordered with tankless heaters, install
heaters with the gaskets provided. Table IV
on Page 37 gives the maximum number of heaters
permissible per assembly and the heater ratings.
2. Plug all boiler tappings and fill boiler completely
with cold water.
3. All completed boilers must satisfactorily pass the
prescribed hydrostatic test.
a. STEAM BOILERS:
be subjected to a hydrostatic test of 45 psig to 55
psig.
b. HOT WATER BOILERS: The assembled boiler
must be subjected to a hydrostatic test of not less
than 1½ times the maximum allowable working
pressure (MAWP).
The assembled boiler must
4. EXAMINE BOILER CAREFULLY, INSIDE AND
OUTSIDE, to insure against leaks from cocked
nipples or through concealed breakage caused in
shipping and handling. This precaution is for your
protection and will simplify handling of necessary
replacements and adjustment claims.
5. After making certain that there are no leaks, drain
boiler and remove plugs for boiler trim and other
connections.
Figure 13: Boiler Section Assembly
18
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 surface of back section. Cut off
excess.
4. Place the canopy on the sections.
5.
Position rear flange (end with studs) of canopy flush
with rear surface of back section.
6. Loosely attach the canopy brackets to the lugs on
the front section of the block assembly with 5/16”
carriage bolts, flat washers and locknuts.
7. Check to see if rear flange of canopy is still flush
with raised flange on back section.
8. Open either the rear flue outlet carton (standard) or
top flue outlet carton (optional).
9. Attach the 1/8” x 1” wide self-adhesive fiber gasket
to the surface of either the rear flue outlet damper
assembly or rear flue outlet cover that mounts
against the canopy and back section. Gasket must
be centered over all attachment holes. Do not
overlap corners, cut butt joints.
10. Attach either the rear flue outlet damper assembly
or rear outlet canopy cover to the canopy with the
5/16” flat washers, lock-washers and brass
nuts and tighten securely. Attach the rear flue
outlet damper assembly or cover to the back section
with the four (4) 5/16” flat washers and cap screws
and tighten securely.
11. Tighten front canopy carriage bolt until canopy is
secure.
12. On the longer canopy sizes, Intermediate Mounting
Brackets are provided, two (2) are required on sizes
24-07 thru 24-09 and four (4) are required on sizes
24-10 thru 24-12A. Refer to Figures 17 and 18.
a. Intermediate brackets are shipped flat. Bend
side flanges down approximately 90° as shown.
Adjust bends until holes in bracket match hole
pattern on canopy.
b. Secure brackets to both sides of canopy with
three (3) #10 x ½” sheet metal screws per
bracket.
c. Secure canopy left side bracket(s) with
appropriate canopy ‘J’ bolt(s). Insert threaded
end through holes in brackets and hook ‘J’ bolt
on center section draw-up rod (hooks should
Damper Assembly (Rear Cover Removed)
Figure 14: Canopy with Rear Flue Outlet
Damper Assembly
Figure 15: Canopy with Top Flue Outlet
19
Figure 16: Bare Boiler Assembly
20
Warning:
Important Product Safety Information
Refractory Ceramic Fiber Product
This product contains refractory ceramic fibers (RCF). RCF has been classified
as a possible human carcinogen. After this product is fired, RCF may, when
exposed to extremely high temperature (>1800F), change into a known human
carcinogen. When disturbed as a result of servicing or repair, RCF becomes
airborne and, if inhaled, may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace previously fired RCF (combustion chamber insulation,
target walls, canopy gasket, flue cover gasket, etc.) or attempt any service or
repair work involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
• Take steps to assure adequate ventilation.
• Wash all exposed body areas gently with soap and water after contact.
• Wash work clothes separately from other laundry and rinse washing ma-
chine after use to avoid contaminating other clothes.
• Discard used RCF components by sealing in an air tight plastic bag.
First Aid Procedures:
• If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
• If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
• If breathing difficulty develops: Leave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing difficulties persist.
• Ingestion: Do not induce vomiting. Drink plenty of water. Seek immediate medical attention.
21
Figure 17: Left Side Canopy Intermediate Bracket Figure 18: Right Side Canopy Intermediate Bracket
face outward). Secure canopy with 5/16” flat
washers, lock washers and brass nuts. See
Figure 17.
d. Secure canopy right side bracket(s) with ¼ - 20
x 5” lg. carriage bolts. Insert head of carriage
bolt between canopy body and casting. Slide
carriage bolt into slot provided between castings.
Lower carriage bolt until threaded end will pass
through hole in bracket. Secure canopy with ¼”
flat washers, lock washers and brass nuts. See
Figure 18.
13. Attach the 1/8” x 1” wide self-adhesive fiber gasket
to the surfaces of either the top flue outlet damper
assembly or top outlet canopy cover that mounts
against the canopy. Gasket must be centered over
all attachment holes. Do not overlap corners, cut
butt joints.
14. Secure either the top flue outlet damper assembly or
top outlet canopy cover with #10 x 1/2” sheet metal
screws.
against boiler and secure with washers and nuts.
Tighten until insulation on cover plate provides a
tight seal to casting. If after tightening, a gap is still
evident where the sections join, apply silastic along
top and bottom edge of insulation board.
5. Repeat steps 3 through 6 for mounting remaining
flue cover plates.
B. INSTALL FLUE COVER PLATES over cleanout
openings on left side of boiler as shown in Figure 19.
See Important Product Safety Information on Page
21 of this manual, regarding refractory ceramic
fiber product warning.
1. Locate the cover plates, carriage bolts, nuts and
washers in the boiler assembly carton(s).
2. Remove insulation from two (2) 3/8” diameter holes
in flue cover plates using a 3/8” drill bit. Rotate bit
through insulation by hand.
3. Attach the carriage bolts to the top and bottom of the
flue openings with washers and hex nuts to provide
a fixed stud.
4. Install flue cover plates over studs with insulation
Figure 19: Flue Cover Plate Attachment
22
C. MOUNT REAR OBSERVATION PORT COVER
NOTICE
To install
multiple s ide panels, sta rt a t th e
rear o f boile r and work forw ard . To re move
pa n els , revers e order of assembly.
PANEL 1 PANEL 2 PANEL 3 PANEL 4 PANEL 5 PANEL 3 PANEL 2 PANEL 1
24-03 L10 L5 - - - 24-03 - - R15 (SINGLE)
24-04 L10 L11 - - - 24-04 - - R21 (SINGLE)
24-05 L10 L17 - - - 24-05 - - R27 (SINGLE)
24-06 L10 L18 L5 - - 24-06 - - R33 (SINGLE)
24-07 L10 L18 L11 - - 24-07 - R15 R24
24-08 L10 L18 L17 - - 24-08 - R21 R24
24-09 L10 L18 L18 L5 - 24-09 - R27 R24
24-10 L10 L18 L18 L11 - 24-10 - R27 R30
24-11 L10 L18 L18 L17 - 24-11 - R33 R30
24-12 L10 L18 L18 L18 L5 24-12 R21 R24 R24
JACKET LEFT SIDE PANEL USAGE CHART RIGHT SIDE PANEL USAGE CHART
BOILER
MODEL
BOILER
MODEL
SINGLE / MULTIPLE RIGHT SIDE PANELS*MULTIPLE LEFT SIDE PANELS*
*NOTE: TO INSTALL MULTIPLE SIDE PANELS, START AT THE REAR AND WORK FORWARD. TO REMOVE PANELS, REVERSE ORDER OF ASSEMBLY.
REAR OF BOILER
FRONT OF BOILER
FRONT OF BOILER
REAR OF BOILER
Refer to Figure 16.
1. With the silastic sealant, secure the 3/16” diameter
rope gasket into the groove around the perimeter of
the rear observation port cover.
2. Mount the rear observation port cover onto the rear
section (with the word “Top” in the upright position)
using the four (4) 5/16” - 18 x 1” lg. cap screws and
flat washers provided.
D. INSPECT ALL BOILER SEALS
1. A visual inspection should be made of all sealed
joints and repairs made as necessary. Darken
the boiler room and place a light source in the
combustion space and canopy to observe any gaps
or open seals. Poor seals must be repaired and
rechecked before continuing.
E. JACKET ASSEMBLY - See Figure 22 for Jacket
Assembly Details.
1. Open jacket carton and jacket hardware package.
Unless otherwise stated, all jacket components are
fastened with #8 x ½” hex head sheet metal screws.
Do not drive sheet metal screws tight until jacket
assembly is complete.
2. On boilers with rear flue outlet damper assembly,
remove square knockout from jacket rear panel. To
remove knockout, use a single hacksaw blade with
handle or aviation snips to cut metal tabs between
slotted holes.
3. Attach jacket front panel to front section and jacket
rear panel to back section using the eight (8) #10
x ½” self tapping screws. Tighten these screws
securely.
4. Attach jacket lower tie bar panel (approximately
5-5/8” high) to the bottom of the jacket front and
rear panels using four (4) sheet metal screws.
Repeat for opposite side.
5. Attach jacket upper tie bar panel (approximately
4-1/8” high) to the top of the jacket front and rear
panels using four (4) sheet metal screws. Repeat for
opposite side.
6. Jacket Top Panel Attachment
a. On boilers with top flue outlet damper assembly,
remove octagon shaped knockout. To remove
knockout, use a single hacksaw blade with handle
or aviation snips to cut metal tabs between
slotted holes.
b. Remove knockout(s) for necessary supply piping
in a similar manner
.
c. Attach jacket top panel to the front panel, rear
panel and upper tie bar panels with sheet metal
screws.
7. Install Jacket side Panels
a. Snap black thumb hole bushings into all side
panel holes.
b. Use the left side panel and right side panel usage
charts to determine correct positions of side
panels. The three (3) digit panel identification
numbers shown in the charts are also stamped
along the bottom edge of each panel. Refer to
Figures 20 and 21.
c. Rearward and Intermediate panels have reverse
bend flanges on one side of panel. These panels
must be installed prior to forward panels.
d. If boiler is equipped with tankless heaters they
should be installed at this time if they were not
installed for hydrostatic test outlined on Page 18.
e. Install right side panels into position by inserting
top of panel into ‘U’ shaped channel, pushing
bottom of panel in toward boiler, and sliding
panel down into ‘J’ shaped channel. Repeat
procedure until all right side panels are in place.
f. Remove the knockouts necessary for tankless
heater operation on left side panels.
g. Install left side panels, using the same procedure
used to install the right side panels.
Figure 20: Left Side Panel Usage Chart
23
Figure 21: Right Side Panel Usage Chart
24
Figure 22: Series 24 Jacket Assembly (Boiler Models 24-03 thru 24-12)
8. Combination Label and Crown Logo Plate were
CAUTION
Fa ilure to properly fill all gap s b etween the
insulatio n a nd burner blast tube may re sult
in damage to the burn er
attached to jacket front panel at time of manufacture.
If loose or peeling, apply pressure to reset adhesive.
9. On steam boilers, attach lowest permissible water
level plate (from steam trim carton) to the front
panel using sheet metal screws.
10. Tighten all sheet metal screws to complete jacket
assembly.
11. RTC Bracket (if used)- install bracket in top right
corner of front panel with four (4) #8 x 3/4” self
tapping screws.
F. BURNER MOUNTING PLATE - Refer to Figures 16
and 23.
1. Using silastic sealant, secure the 3/16” diameter
rope gasket to the groove along the mounting plate
opening in the front section.
2. Install 5/16” x 1” lg. cap screw in lower tapping on
front section to carry weight of burner mounting
plate.
3. Engage bottom slot on burner mounting plate with
matching bolt in bottom tapping of front section.
Align mounting holes and fasten the mounting plate
to the boiler sections with seven (7) remaining 5/16”
cap screws and washers. Fully tighten all bolts.
Apply four (4) small dabs of silastic on rear surface
of adapter plate to temporarily hold gasket in
place. Hold adapter plate in position against burner
mounting plate, align holes and secure with five (5)
3/8” lock washers and 3/8” x 7/8” lg. cap screws.
3. Follow burner manufacturer’s instructions using
gasket material and hardware provided with burner.
4. USE A HOLE SAW OR KNIFE TO CUT BURNER
MOUNTING PLATE INSULATION TO MATCH
HOLE SIZE ON BURNER ADAPTER PLATE.
After cutting, remove any and all loose pieces of
insulation which may become lodged or interfere
with the head of a burner air tube after insertion.
Confirm that hole in insulation fits snugly around
burner blast tube. If hole is oversized, use fiberglass
rope gasket provided with burner to fill in any space
between insulation and blast tube. If rope gasket
is not provided with the burner, use 3/8” fiberglass
rope (provided by others).
5. For boilers without tankless heaters, proceed
to Step H (Install Steam Trim) or I (Install Water
Trim).
6. For boilers with tankless heaters, install the
tankless heater manifolds according to Figure 37.
G. MOUNT BURNER ADAPTER PLATE TO
BURNER MOUNTING PLATE.
Refer to Figures 16 and 23.
1. In all cases the burner adapter plate carton for the
specified burner will be provided by Crown.
2. Open Adaptor Plate carton and remove contents.
Figure 23: Burner Mounting Plate/Burner Adapter Plate Options
25
Size Size
(in) (in)
B 4
Plug (24-03 thru 24-06)
Supply (24-07 thru 24-12)
K
Steam Boiler
A 4 Supply
Tapping
Location
Steam Boiler
Tapping
Location
C
3 Blow-Off Valve
D 3 Return
E 3 Plug
J1 1
F 3 Plug
G 1-1/2 Safety Valve/Surface Skim Tap
Plug
J2 1 Float L.W.C.O.
3/4 Plug
M 3/4 Operating Pressure Limit Control
N 3/4
Hi Pressure
Limit Control/Manual Reset
P 1/2 Gauge Glass/#67 L.W.C.O.
Q 1/2 Steam Gauge (Bush to 1/4")
S 3/4 Tankless Heater Control
T 3/4 Firing Rate Pressure Control
Figure 25a Purpose of Tappings - Steam Boilers
26
1 1/2" X 3" BR NIPPLE ALL 2 29 1" X 12" NIPPLE
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
1
2 1/2" BR UNION ALL 2 30 4" BK PLUG ALL 1
3 1/2" BR CLOSE NIPPLE ALL 2 31 1-1/2" X 4 NIPPLE ALL 1
4 LWCO, #67 ALL 2 32 1-1/2" TEE ALL 1
5 GAUGE GLASS SET ALL 2 33 1-1/2" SQ. HD. PLUG ALL 1
6 3" SQ. HD. PLUG ALL 2 34 1-1/2" x 3/4" BLK BUSHING 24-03 1
7 3/4" X 2" NIPPLE ALL 1 34 1-1/2" x 1" BLK BUSHING 24-04 1
8 3/4" UNION ALL 1 34 1-1/2" x 1-1/4" BLK BUSHING 24-05 THRU 24-08 1
9 3/4" X 1/4" HEX BUSHING ALL 1 1 1 35 3/4" CLOSE NIPPLE 24-03 1
10 1/4" 90° BR PIGTAIL ALL 1 1 1 35 1" CLOSE NIPPLE 24-04 1
11 L404C1147
CSD-1 EQUIPPED BOILERS
1 35 1-1/4" CLOSE NIPPLE 24-05 THRU 24-08 1
12 1/2" X 1/4" BR BUSHING ALL 1 35 1-1/2" CLOSE NIPPLE 24-09 THRU 24-12 1
13 PRESSURE GAUGE ALL 1 36 SAFETY VALVE 13-211 24-03 1
14 3/4" RECESSED HD PLUG ALL 1 36 SAFETY VALVE 13-202 24-04 1
15 3/4" BLK EXTENSION ALL 1 1 36 SAFETY VALVE 13-213 24-05 THRU 24-08 1
16 L404F1367 ALL 1 36 SAFETY VALVE 13-214 24-09 THRU 24-12 1
17 FIRING RATE PRES CTRL
MODULATING BOILERS
1 37 3" X 1-1/4" BLK BUSHING ALL 1
18 1" X 5-1/2" NIPPLE
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
1 38 1-1/4" X 3/4" BUSHING 24-03 THRU 24-04 1
19 1" UNION
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
2 38 1-1/4" X 1" BUSHING 24-05 THRU 24-08 1
20 1" X 3-1/2" NIPPLE
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
2 39 3/4" CLOSE NIPPLE 24-03 THRU 24-04
1
21 1" CLOSE NIPPLE
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
1 39 1" CLOSE NIPPLE 24-05 THRU 24-08
1
22 1" BALL VALVE
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
1 39 1-1/4" CLOSE NIPPLE 24-09 THRU 24-12
1
23 1" RECESSED HD PLUG
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
4 3 40 3/4" BALL VALVE 24-03 THRU 24-04
1
24 1" CROSS
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
3 40 1" BALL VALVE 24-05 THRU 24-08
1
25 1" NIPPLE*
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
1 40 1-1/4" BALL VALVE 24-09 THRU 24-12
1
26 #150-MD LWCO
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
1 41 3/4" SQ. HD. PLUG 24-03 THRU 24-04
1
26 #64 LWCO
CSD-1 EQUIPPED BOILERS
GRAVITY RETURN
1 41 1" SQ. HD. PLUG 24-05 THRU 24-08
1
27 1" NIPPLE**
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
1 41 1-1/4" SQ. HD. PLUG 24-09 THRU 24-12
1
28 1" NIPPLE***
CSD-1 EQUIPPED BOILERS
PUMPED RETURN
1
*SIZE NIPPLE TO SET WATER LEVEL OF LWCO.
**SIZE NIPPLE TO MAKE UP LENGTH BETWEEN 24 & 26.
QUANTITY
KEY DESCRIPTION BOILER MODELS DESCRIPTION BOILER MODELS
QUANTITY
KEY
OPTIONAL
NOT
SUPPLIED
STANDARD
***SIZE NIPPLE TO MAKE UP LENGTH BETWEEN 19 & 24.
STANDARD
OPTIONAL
NOT
SUPPLIED
Figure 25b: Steam Trim
27
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