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TABLE OF CONTENTS
SECTION I - GENERAL INFORMATION
Dimensional Information ................................................................................................................. 10
Ratings/Data .......................................................................................................................................12
Locating the Unit . .............................................................................................................................13
Air Supply/Venting .............................................................................................................................14
SECTION II - CAST IRON BLOCK ASSEMBLY INSTRUCTIONS (Knockdown Boiler)
Knockdown Boiler w/ Factory Assembled Section ........................................................................17
Assembly of Sections, Manual Draw-up ........................................................................................18
Assembly of Sections, Hydraulic Draw-up ....................................................................................23
Hydrostatic Test ................................................................................................................................24
SECTION III - BOILER ASSEMBLY INSTRUCTIONS (Knockdown Boiler)
Install Common Parts to Block (Hinge Hardware, Flue Collector, Clean-out Covers, Etc.) ......25
Install Supply and Return Manifolds ..............................................................................................27
Install Return Water Mixing Tube .....................................................................................................27
Install Jacket Support Frame to Block ............................................................................................30
Install Heat Exchanger Insulation ....................................................................................................37
Install Internal Wiring Harness Components .................................................................................38
Install Jacket Top Corner Panels ....................................................................................................43
Install Jacket Front and Rear Panels ..............................................................................................44
Install Jacket T
op and Side Panels . ................................................................................................45
Install Burner Swing Door (BSD) ....................................................................................................47
Install 2
nd
and 3
rd
Pass Flueway Bafes...........................................................................................49
Procedure to Close and Secure Burner Swing Door .....................................................................50
Install Burner Adapter Plate and Mount Burner (Burner Specic) ...............................................50
Connecting Internal Wiring Harness to Burner Controls ..............................................................51
Install Standard Water Trim and Control .........................................................................................52
Install Optional Controls:
• Probe LWCO .............................................................................................................................54
• High Limit Control w/ Manual Reset ......................................................................................54
• Low Fire Hold Control .............................................................................................................54
• Low / High / Low Control or Modulating Control ..................................................................55
Install Flue Outlet Damper Assembly ..............................................................................................56
Install Optional Burner Swing Door Cover Split Jacket Panels ....................................................57
SECTION IV - INSTALLATION INSTRUCTIONS
Packaged Boiler - Shipping Information .........................................................................................58
Boiler Piping - Heating Applications................................................................................................58
Boiler Piping - Domestic Hot Water .................................................................................................64
Relief Valve Piping .............................................................................................................................64
Electric Wiring ...................................................................................................................................64
SECTION V - OPERATING INSTRUCTIONS
Filling System ....................................................................................................................................65
Adjusting Controls ............................................................................................................................65
Adjusting Burner ...............................................................................................................................65
Test Controls ......................................................................................................................................66
Initial Cleaning, Water Boilers ..........................................................................................................66
Frequent Water Addition ...................................................................................................................67
Oxygen Corrosion .............................................................................................................................67