CleaverBrooks FLX Operation, Service And Parts Manual page 91

Inspection and Maintenance
The flue outlet and stack should also be inspected annually
and cleaned as necessary. Commercial firms are available to
perform this work. The stack should also be inspected for
damage and repaired as required.
Once everything has been cleaned and inspected the boiler
can be put back together. Install insulation blocks in the 2nd
and 4th pass openings in their previous positions. Spray
adhesive on tubes above and below pass opening and install
blanket insulation over opening. Install cover plates on 2nd
pass (left) side only. If any insulation was removed from
under the tubes at bottom of boiler it should be replaced at
this time.
Prior to installing the inner casing, inspect studs on boiler and
bolt bars for any thread damage. Any damaged threads
should be cleaned and chased with a 3/8"-16 die. Apply a
small amount of Cleaver-Brooks "Never-Seez" (p.n. 797-
1814 or 797-1816) on each stud.
Before the inner casing can be installed, the old gaskets must
be removed from the panels and around the perimeter of the
boiler and replaced with new ones. After removing the
gaskets, the surfaces should be cleaned to allow the new
gasket to seal properly. The gasket around the perimeter of
the boiler should be one piece with the ends overlapping side
by side somewhere along the upper (roof) surface. A small
amount of silicone will be required to fill gaps and valleys
where the gasket crosses. This includes the roof to end wall
seams and the base angle to end wall gaps. It is important that
the entire gap between the end wall and the base angle be
completely sealed. The seal along the base of the end wall
should also be checked and resealed if necessary. The gasket
should be positioned to the inside of the studs with a 1/4" gap
between the studs and the gasket.
750-177
Figure 7-1 Gasket application to inner casing
Install gasket on side casing panels so it extends past the top
and bottom by 1/4" or more and 1/16" to 1/8" out the back at
the top and bottom of the panel. (See Figure 7-1). Starting
from one end, set panel edge 1/8" to 1/4" from the studs on
the end wall. Install the first lower clamp angle over the
respective studs, install washers and start nuts. Any nuts that
are difficult to install should be replaced. Place the upper
clamp angle over the top studs and install washers and nuts
but don't tighten. The end clamp can now be installed and
nuts on the end clamp can be snugged up but not completely
tightened. Before installing the next panel, apply a small
amount of teflon paste to the area where the vertical gasket
and the horizontal gaskets will overlap at the top and bottom.
This will help ensure an air tight seal. Install the next panel in
line being careful to slide the 1" gasket retaining strip behind
the panel but under the insulation. Install the bottom and top
clamp angles to hold panel in place, but don't tighten. Install
the bolt strips, washers and nuts which clamp the panels
together. Pull panels together evenly and tighten nuts to 250
to 300 in-lbs. Repeat until all panels are installed and securely
bolted together. Now panels can be evenly pulled toward
boiler with clamp angles. Tighten all nuts to 250 to 300 in-lbs.
The outer casing panels can now be installed starting with the
end panels. Slide each end panel under the upper frame and
push the bottom section into the boiler and allowing it to slide
down to catch the bottom clamp angle. Then slide the end
panels under the corner frames and install any remaining
center panels.
The fireside should be thoroughly cleaned prior to any
extended layup of the boiler. Depending upon circumstances,
a protective coating may be required. See Chapter 3, Section
H "Preparation for Extended Layup".
Chapter 7
7-3