Pictorial: the DF520 Stoker Base and Boiler

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stoker-man
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Location: Lehigh Valley, PA
Hand Fed Coal Boiler: 1981 efm wcb-24 in use 365 days a year
Coal Size/Type: Anthracite/Chestnut
Other Heating: Hearthstone wood stove

Post by stoker-man » Mon. Dec. 31, 2007 6:30 pm

Pictorial: The DF520 Stoker Base and Boiler, Final Assembly

Pictorial: Showing all parts, parts numbers and sequence of assembly

CLICK ON ANY PICTURE FOR A LARGER VIEW

NONE OF THE PICTURES SHOW THE JACKET, WHICH SURROUNDS THE ENTIRE BOILER/BASE ASSEMBLY

1stoker-mounting-plate.jpg

9542592 Stoker mounting plate

The stoker fan housing is bolted to the mounting plate. The assembly spacer ring is positioned between the stoker fan housing and the stoker mounting plate with the flange facing up and outward. This flange will hold the equipment hood in place. Using four 3/8 X 1 ¾” bolts, the assembly is fastened to the stoker mounting plate and then mounted in the base as shown in a subsequent picture.

The stoker can be mounted on either side of the base, depending upon the location of the coal bin.

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1-spacer-ring.jpg

Spacer ring installed, proper direction of hood flange

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assembly-spacer-ring.jpg

9536410-1 Assembly spacer ring

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1boiler on base stoker side.jpg

The installed stoker mechanism. The damper assembly is shown above the stoker and is used for the optional oil burner kit.

The next steps would be to install the air pipe, the burner pot assembly and the cleanout rod and lever.

All these steps are detailed in the post: Pictorial: Combining of the Stoker and Burner Pot assemblies.

Click link below and scroll down to the pictorial and explanations.

.JPG | 1.1MB | 1boiler on base stoker side.jpg
1burner-end-pipe-insertion-.jpg

The burner end pipe is now inserted into the burner pot assembly with the series of drilled holes, in the pipe, facing upward towards the boiler. (In this picture, they are shown facing downward) The notch in the pipe is aligned with the roll pin, and fastened with the two set screws.

The burner end worm can now be inserted through the pipe and gooseneck and attached to the clutch assembly with the cotter pin.

.JPG | 1.7MB | 1burner-end-pipe-insertion-.jpg
1boiler-on-base-bin-feed-si.jpg

The bin side plate is placed in position to support the pipe.

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1bin-side-plate.jpg

9542596 Bin side plate

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bin-pipe-collar.jpg

9536409 Bin pipe collar

The bin feed pipe collar, with 21” of rope gasket underneath and wrapped around the pipe, is secured to the bin side plate with three self-tapping screws. The rope gasket is necessary to seal all air leaks around the pipe.

.JPG | 150.7KB | bin-pipe-collar.jpg
Baffle-plate.jpg

9542994-2 Baffle plate, 2 required per unit

.JPG | 1.5MB | Baffle-plate.jpg
1boiler-on-base-fire-door-s.jpg

The boiler is set upon the base. The boiler baffles are shown in the rear of the boiler. There is another cast iron baffle at an angle above the boiler baffle plates, not shown in the picture.

.JPG | 1001.8KB | 1boiler-on-base-fire-door-s.jpg
cast-iron-baffle.jpg

9541331 Cast iron baffle

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1rear-panel.jpg

9542594 Rear panel

.JPG | 197.7KB | 1rear-panel.jpg
1boiler-on-base-coil-side.jpg

The rear panel is installed onto the base.

.JPG | 1.1MB | 1boiler-on-base-coil-side.jpg
1-ash-can-guide.jpg

9542610 Ash tub guide

.JPG | 338.4KB | 1-ash-can-guide.jpg
1-ash-can.jpg

35591 Ash tub

.JPG | 512.9KB | 1-ash-can.jpg
1-ash-pit-door.jpg

7042598 Ash pit door

.JPG | 642KB | 1-ash-pit-door.jpg
1-ash-pit-door-handle.jpg

73319 Ash pit door handle

.JPG | 657.2KB | 1-ash-pit-door-handle.jpg
1gear-oil.jpg

9433463K Gear oil

Before installing the mechanism hood, the gear oil reservoir is filled to a level about 3/8" above the bottom of the lowest gear level. See the operators manual on the efm website. www.efmheating.com

.JPG | 973.5KB | 1gear-oil.jpg
1-hood-installed.jpg

7051846 Mechanism hood installed

.JPG | 745KB | 1-hood-installed.jpg
1-fire-door.jpg

7052197 Fire door

.JPG | 1.2MB | 1-fire-door.jpg
1-boiler-putty.jpg

39104 Boiler Putty
Boiler putty is applied around all panels, any cracks, and any area where air could infiltrate or escape.

.JPG | 445.8KB | 1-boiler-putty.jpg
1-boiler-water-conditioner.jpg

9535472K Steam Boiler water conditioner
Water conditioner is recommended for all steam boilers

.JPG | 535.8KB | 1-boiler-water-conditioner.jpg
Boiler-water-conditioner.jpg

38109 Hot Water Boiler water conditioner
Water conditioner is recommended for all hot water boilers

.JPG | 652.2KB | Boiler-water-conditioner.jpg
Aquastat-well.jpg

73240 Aquastat well

Installed into the boiler.

.JPG | 566.3KB | Aquastat-well.jpg

 
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Dennis
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Post by Dennis » Sun. Nov. 03, 2019 12:34 pm

I just bought a new df520,do i need to seal all the base panels while putting together,if so is it better to use high temp silicone between each panel and"blind caulk" then bolt together

 
lzaharis
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Post by lzaharis » Sun. Nov. 03, 2019 1:59 pm

They do not supply any gaskets with the boiler?????

The only way your going to know if the high temperature silicone is sealing the base and the pressure vessel is to
seal and assemble it as you go with a thick bead of high temperature silicone and then pressurize it with the fan and use a lit cigar or propane torch to see if there are any leaks along the mating surfaces.

If you have an air leak you will have to start all over again as you do not want flue gasses from the firebox entering the home.

Oatey Furnace Cement would serve you better and a small pail of it is not that expensive.


 
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Rob R.
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Post by Rob R. » Sun. Nov. 03, 2019 2:16 pm

Dennis wrote:
Sun. Nov. 03, 2019 12:34 pm
I just bought a new df520,do i need to seal all the base panels while putting together,if so is it better to use high temp silicone between each panel and"blind caulk" then bolt together
High temp. silicone works fine.

 
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Dennis
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Hand Fed Coal Boiler: AHS/WOC55-multi-fuel/wood,oil,coal
Coal Size/Type: Anthracite/stove size

Post by Dennis » Sun. Nov. 03, 2019 2:59 pm

Rob R. wrote:
Sun. Nov. 03, 2019 2:16 pm
High temp. silicone works fine.
thanks, already done

 
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coalkirk
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Post by coalkirk » Sun. Nov. 03, 2019 3:36 pm

That’s what I used. No air leaks


 
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StokerDon
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Post by StokerDon » Sun. Nov. 03, 2019 4:54 pm

Dennis wrote:
Sun. Nov. 03, 2019 2:59 pm
thanks, already done
Sorry Denis, I don't believe you. There are no pictures. :lol:

-Don

 
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Dennis
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Post by Dennis » Sun. Nov. 03, 2019 6:54 pm

Attachments

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StokerDon
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Joined: Mon. Nov. 11, 2013 11:17 am
Location: PA, Southern York County!
Stoker Coal Boiler: Gentleman Janitor GJ-5, Van Wert VA-600, Axeman Anderson130 X3.
Hand Fed Coal Furnace: Harman SF3500 reduced down to 3 grates connected to its own plenum
Coal Size/Type: Rice, Chestnut and whatever will fit through the door on the Harman
Other Heating: Noth'in but COAL! Well, Maybe a little tiny bit of wood

Post by StokerDon » Sun. Nov. 03, 2019 7:37 pm

Wow, it is new!

-Don

 
CapeCoaler
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Post by CapeCoaler » Sun. Nov. 03, 2019 9:14 pm

Brand spankin'...
LOL...

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