Crown Boiler 16-325 500506 - Manual (Page 8)

8
V Knockdown Boiler Assembly Instructions
6
A. Prior To Assembly
1) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or
punctures due to mishandling.
2) Do not use a damaged heat exchanger.
3) All joints between sections have been factory sealed. Inspect the joints between the sections for openings due as a
result of shipping and handling. Reseal any openings with furnace cement.
4) All joints between the base and the heat exchanger have been factory sealed. Inspect the joints between the base and
the heat exchanger for openings due as a result of shipping and handling. Reseal any openings with furnace cement.
5) All joints between the flue collector and the heat exchanger have been factory sealed. Inspect the seal between the
flue collector and the heat exchanger for openings due as a result of shipping and handling. Reseal any openings
with furnace cement.
6) Confirm the tie rods are only hand tight to allow for thermal expansion.
7) Review all of the installation requirements in this installation manual.
8) Verify that all needed components are on hand. A complete list of all cartons along with their contents can be
found in the Parts Section of this manual.
B. Boiler (Base, Heat Exchanger, Flue Collector) Assembly, Installation & Leak Testing
1) Each boiler assembly (base, heat exchanger, flue collector combination) is tested and shipped as a single unit.
2) Place the base, heat exchanger and flue collector assembly in close proximity to the final location. Refer to Sections
III and IV in this manual for additional information on placement.
3) Remove all packaging material, protective spacers and bracing from the assembly.
4) Remove the base hold down bolts used to anchor the assembly to the skid.
5) Exercise care to avoid dropping the boiler while removing it from the skid.
6) Leak test the heat exchanger before installing the jacket, trim and controls. Refer to Figure 4 and Table 4 for
tapping locations and sizes.
a. Plug tappings C, F and return tapping B. Tapping E is plugged at the factory.
b. Insert a 3/4” x 1/4” NPT bushing in tapping D and install a pressure gauge with a mid-range of 50 psi in this
location.
c. Insert a 2” x 3/4” NPT bushing in supply tapping A and install a purge valve with a hose that runs to a drain in
this location.
d. Connect a fill valve and piping to the drain tapping G.
e. Fill the heat exchanger completely with water and vent the air through the purge valve. Slowly close the purge
valve and apply water pressure of at least 10 psi but less than 50 psi gauge. DO NOT EXCEED THE 50 PSI
LIMIT.
f. Carefully examine all parts of the heat exchanger assembly for leaks.
g. Drain the heat exchanger and remove plugs from tappings B & C. Also remove the fill valve, purge valve
pressure gauge and related piping used in the leak test.
7) Installation on combustible flooring requires the use of a special base designed and approved for use on combustible
floors. See Figure 5. This special base adds 4-3/4” to the overall boiler height. Follow the instructions below if a
special base is required.
a. Place special base on combustible floor with surface marked "FRONT" in upward position.
b. Locate special base with spacing to combustible materials as shown in Figure 5.
c. Place the base, heat exchanger and flue collector assembly on the special base. The assembly must rest inside
locating brackets. Note that the boiler jacket panels will overhang special base.
d. Do not enclose boiler, or special base on all four sides. Models 16-325 and 16-390 may be enclosed on
three sides (alcove) while maintaining clearances shown in Figure 2.