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II. Unpack Boiler
CAUTION
Do not drop boiler. Do not bump boiler jacket
against floor.
A. REMOVE CRATE
1. Remove all fasteners at crate skid.
2. Lift outside container and remove all other inside
protective spacers and bracing. Remove vacuum
relief valve and miscellaneous trim bag containing
safety/relief valve, and pipe fittings.
B. REMOVAL OF BOILER FROM SKID
1. Boiler is secured to base with 2 bolts, 1 at left front
and 1 at right rear. Remove both bolts.
2. Tilt boiler, "walk" boiler backward, and set rear
legs down on floor. Tilt boiler backward, pull skid
forward and set front legs down on edge of skid.
Install close nipple, tee, and plug in return
coupling. See Section III and Figure 5. Point tee
toward permanent return location.
3. Tilt boiler backward and remove skid. Be careful
not to damage Burner or Jacket.
C. DETERMINE PROPER HINGE LOCATION FOR
BURNER SWING DOOR. Boiler is shipped with
hinges on left side. Approximately 12 inches are
required on the hinge side for burner clearance. If
there will be less than 12 inches from left side of boiler
to wall, move hinges to right side (refer to Paragraph
D).
D. HINGE LOCATION CHANGE (if required).
1. Pull 2 halves of Burner Swing Door Interlock apart.
Swing Door Interlock is connected to R-W
terminals on R8184P Control. Lift Honeywell
R8184P Control off of Burner Junction Box and
disconnect wiring harness from burner.
2. Remove 8 sheet metal screws from jacket. Remove
rear jacket box and bend both sides of Jacket
Wrapper up, see Figure 20.
3. Remove 2 (two) 5/16" - 18 x 3" long hex head cap
screws and flat washers from right side of door.
Remove 2 hairpin cotter pins and 2 hinge pins from
hinges on left side of door and remove Door
Assembly from boiler. Inspect Front and Rear Door
Insulation Pieces and Combustion Chamber Liner,
see Paragraph G.
4. Remove 4 hex nuts from bolts that attach hinges
and hinge spacers to left side of Tubesheet. Remove
4 hex head cap screws that attach hinges to door.
5. Attach 2 hinge brackets & spacers to Tubesheet and
2 hinge brackets to Door on right side of boiler. 3
Holes in each Hinge Bracket must line up with 3
matching holes in Spacer, Tubesheet or Door. See
Figure 3. Tighten hex nuts, bolts and screws by
hand only.
6. Replace door assembly. Hinge brackets attached to
door must rest on top of hinge brackets attached to
tubesheet. See Figure 4. Slide hinge pins through
hinges from top and install cotter pins. Close door
and install 5/16" - 18 x 3" long hex head cap
screws through flat washers and left side of door
and into tapped holes in tubesheet. Tighten all hex
nuts, bolts and screws. When door is installed
properly, it is parallel to Tubesheet when viewed
from top and sides.
7. Bend sides of Jacket Wrapper down and attach 2
Jacket Straps to 4 slots at bottom of Jacket Wrapper
sides with sheet metal screws. Install Rear Jacket
Box with 4 sheet metal screws. See Figure 20.
8. Connect wiring harness to burner Junction Box and
install Honeywell R8184P Control, see Wiring
Diagram, Figure 15.
Reconnect Swing Door Interlock.
E. INSTALL BOILER CONTROL.
1. Pull bulb and capillary tube out of hole in back of
control. Insert bulb in immersion well on top of
boiler and secure control with set screw in control.
2. Secure flexible conduit to Jacket Wrapper side with
conduit clamp and sheet metal screw. Conduit
must be on same side of boiler as Swing Door
hinges.
F. MOVE BOILER TO PERMANENT POSITION by
sliding or walking.
G. INSPECT FRONT AND REAR DOOR INSULATION
AND COMBUSTION CHAMBER LINER
1. OPEN BURNER SWING DOOR on front of boiler.
Use flashlight to inspect insulation secured to front
and rear doors. Inspect ceramic fiber blanket
secured to bottom of combustion chamber. Inspect
inner and outer door gaskets. Replace any damaged
pieces.