Install Instructions
15
Figure 11: Limit Sensor Insertion
k. Reinstall nozzle line electrode assembly.
l. Reconnect copper connector tube.
m. Tighten knurled nut.
n. Close igniter, rotate and tighten two (2) igniter
latching screws.
G. INSTALL WATER BOILER TRIM AND
CONTROLS, (see Figures 1A and 1B).
1. Install return piping supplied with boiler. Apply
Teon or Sealant to all joints prior to assembly.
Thread 1½" NPT x 5" Lg. return nipple into 1½"
NPT tapping located in lower left corner of front
section. Thread 1½" x ¾" x 1½" NPT tee onto
5" nipple. Thread ¾" drain valve into ¾" NPT
connection on tee. Tighten all joints with wrench
until water tight and 1½" NPT return connection on
tee is facing away from boiler horizontally to allow
for proper burner swing door clearance, see Figures
1A, 1B, 12A and 12B.
Note: Vertical piping will prevent door from opening
fully for service and cleaning of boiler.
2. Thread relief valve onto factory installed ¾" NPT
x 7¼" nipple located in left rear corner on top
of boiler as shown in Figures 1A and 1B. Valve
spindle must be in vertical position. Tighten with
wrench. Pipe discharge as shown in Figures 12A
and 12B. Installation of the relief valve must be
consistent with ANSI/ASME Boiler and Pressure
Vessel Code, Section IV.
3. Connect Field Wiring
Connect the eld wiring to the Warm or Cold Start
Intelligent Oil Boiler Control (Boiler Control).
Make the wiring connections as shown in Figure 21
and 22.
a. On water boilers without rear tankless heater,
connect the eld wiring from the circulator to
the Cold Start Boiler Control and from the Cold
Start Boiler Control to the Burner Oil Primary
Control. Make the wiring connections as shown
on Figure 21.
III: INSTALLATION INSTRUCTIONS (continued)
b. On water boilers with rear tankless heater, the
factory wired Warm Start Boiler Control was not
installed in heater. Locate 3/4" NPT immersion
well, apply sealant, thread into 3/4" NPT tapping
on tankless heater and tighten with wrench.
Apply heat transfer paste (not furnished) to
limit sensor and fully insert limit sensor into
immersion well such that the tip on the limit
sensor touches the bottom of the immersion well.
See Figure 11. Tighten clamp screws to secure
Warm Start Boiler Control to immersion well.
Secure Boiler Control conduit to jacket right
side panel with 5/8" cable clamp provided, refer
to Figure 1B. Make the wiring connections as
shown on Figure 22.
Figure 10: Electrode Settings
H. INSTALL STEAM BOILER TRIM AND
CONTROLS, (SEE FIGURE 1C).
1. Thread ¾" MPT safety valve and ¾" NPT coupling
onto factory installed ¾" NPT x 7¼" nipple located
in left rear corner on top of boiler as shown in
Figure 1C. Tighten with wrench. Pipe discharge as
shown in Figure 13. Installation of the relief valve
must be consistent with ANSI/ASME Boiler and
Pressure Vessel Code, Section IV.
2. Install ¾" drain valve in wet return piping as shown
in Figure 13.
3. On boilers with rear tankless heater, factory
wired L4006A Aquastat Heater Control was not
installed in heater. Locate ¾" NPT Immersion Well,
apply sealant and thread into ¾" NPT tapping on
heater. Apply heat transfer paste (not furnished) to
control bulb and insert bulb into immersion well.
Tighten clamping screws to secure Boiler Control
to immersion well. Secure 18/2 Control Cable Wire
to jacket right side panel with 5/16" cable clamp
provided, refer to Figure 1C.