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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 fits snugly around rear section
tankless heater collar/ mounting flange (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 identification.
2. Place Left Side Jacket Panel over four #8 x ½"
shoulder sheet metal screws, earlier installed at
Front and Rear Jacket Panel side flanges, so teardrop
cutouts in the side panel inside flanges 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 identification.
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 flange, over four
#8 x ½" shoulder sheet metal screws, previously
installed at Front and Rear Jacket Panel side flanges,
so teardrop cutouts in the side panel inside flanges
engage all four screws simultaneously.
7. Slide the panel downwards to lock all screws
securely.
8. Pick up Top Jacket Panel from Jacket Carton.
9. Place the panel between side panels upper inside
flanges and slide it forward, until top panel front
flange U-bend locks over front panel top flange, and,
top panel rear flange is positioned over rear jacket
panel.
10. Locate/remove two #8 x ½" sheet metal screws from
Hardware Bag.
11. Install both screws into top panel rear flange to
secure the top panel to rear jacket panel.
k. ExTERNAL ELECTRICAL ENCLOSURE
MOUNTING.
1. Remove two #8 x ½" shoulder sheet metal screws
and one #8 x ½" sheet metal screw from Hardware
Bag.
2. Install both #8 x ½" shoulder sheet metal screws
into Right Side Jacket Panel, at two upper corners of
the panel front cutout.
3. Locate and remove External Electrical Enclosure
assembly from Control Carton.
4. Remove the enclosure cover and set aside.
5. Pick Molex connector end of Burner Harness and
feed it inside the enclosure, thru bushed hole at
enclosure lower left corner, next to transformer/
relay.
6. Place the enclosure over installed shoulder sheet
metal screws, so teardrop cutouts in the enclosure
base engage both screws simultaneously, then, slide
the enclosure downwards to lock it in place.
7. Install #8 x ½" sheet metal screw thru enclosure
base lower hole, located to the right of transformer/
relay, into right side panel to secure the enclosure.
8. Plug-in burner harness Molex connector into
dedicated burner harness receptacle inside the
enclosure (lower left off transformer/relay). See "
Control Plug-In Diagram" label attached to inside of
the enclosure cover for details.
9. Do not install the enclosure cover yet; proceed to
control installation.
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