Install Instructions

17
7. Secure panel bottom to studs with acorn nuts hand
tight.
8. Align upper panel attachment holes with smokebox
upper attachment bosses and install 5/16”-18 x ½”
Phillips pan head machine screws hand tight.
9. Securely tighten rear jacket panel mounting
hardware.
10. Locate/remove four #8 x ½” shoulder sheet metal
screws from Hardware Bag, then, install them into
rear panel ange holes.
H. FLUE CLEANOUT COVERS AND SMOKEBOX
COLLAR INSTALLATION.
1. Remove two cast iron Cleanout Covers, cast iron
Smokebox Collar and the tube of hi-temperature
silicon adhesive sealant from Part Carton. See also
“Repair Parts” Section, “Bare Boiler Assembly”
illustration for part identication.
2. Check the rope gasket factory attached to the covers.
Repair or replace, if the rope is damaged, or, there is
a gap between the rope ends.
3. Locate/remove four 5/16”-18 – 7/8” hex head cap
screws from Hardware Bag.
4. Apply a drop of supplied Anti-seize (pouch provided
in Part Carton) to each of four (4) 5/16”-18 x 7/8”
hex head cap screws for rust protection and to
facilitate easy removal for future service.
5. Position left Cleanout Cover over rear section
cleanout opening, align section boss holes with
Cleanout Cover holes, install both 5/16”-18 – 7/8”
hex head cap screws hand tight, then, alternately
tighten them with open end or socket wrench.
6. Repeat above steps with right Cleanout Cover.
7. Apply the adhesive sealant to the underside of the
collar, all around, at the inside corner of the collar
outer ring. Insure adhesive bead is complete all
around and without gaps.
8. Place the collar over smokebox tongue and align
collar integral mounting ear slots with smokebox
bosses.
9. Thread-in both 5/16”-18 – 7/8” hex head cap screws
hand tight, then, alternately tighten them with open
end or socket wrench.
I. INSULATION WRAPPER AND BURNER
POWER OUTLET RECEPTACLE WITH
HARNESS INSTALLATION.
1. Insulation Wrapper is vacuum packed/sealed in
plastic bag at the factory.
2. Carefully cut the plastic bag and remove Insulation
Wrapper. The wrapper will expand upon removal.
3. Unfold Insulation Wrapper, position it over section
assembly centered left to right and align two
wrapper upper holes with 2" NPT pipe tappings in
front and rear section top.
4. Insure wrapper ts snugly around rear section
tankless heater collar/ mounting ange (if boiler
is equipped with tankless heater) and trim the
insulation at tankless heater cutout. Do not trim off
insulation on boilers having non-heater rear section.
5. Tack Insulation Wrapper bottom ends under section
assembly, between front and rear section legs.
6. Locate and remove Burner Power Outlet Receptacle
with factory attached Burner Harness from Control
Carton.
7. Feed Molex end of Burner Harness thru front jacket
panel right side outlet receptacle cutout. Insure
that the receptacle middle prong opening is facing
down. Snap the receptacle into front jacket panel.
Temporarily, stuff Molex end of Burner Harness
between front panel insulation and insulation
wrapper near boiler top.
J. SIDE AND TOP JACKET PANEL
INSTALLATION.
1. Pick up Left Side Jacket Panel from Jacket Carton.
See also “Repair Parts” Section, “Jacket Assembly”
illustration for part identication.
2. Place Left Side Jacket Panel over four #8 x ½”
shoulder sheet metal screws, earlier installed at
Front and Rear Jacket Panel side anges, so teardrop
cutouts in the side panel inside anges engage all
four screws simultaneously.
3. Slide the panel downwards to lock all screws
securely.
4. Pick up Right Side Jacket Panel from Jacket Carton.
See also “Repair Parts” Section, “Jacket Assembly”
illustration for part identication.
5. Pick up Molex end of Burner Harness stuffed
between front panel insulation and insulation
wrapper and feed it thru Right Side Jacket Panel
front cutout, letting the harness connector to hang
over the cutout edge temporarily.
6. Place Right Side Jacket Panel, clearing rear section
tankless heater collar/ mounting ange, over four
#8 x ½” shoulder sheet metal screws, previously
installed at Front and Rear Jacket Panel side anges,
so teardrop cutouts in the side panel inside anges
engage all four screws simultaneously.
7. Slide the panel downwards to lock all screws
securely.
8. Pick up Top Jacket Panel from Jacket Carton.
SECTION II: UNIT-PAK BOILER ASSEMBLY (continued)