HOT WATER BOILER ( MBH)

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1 GAS-FIRED DIRECT VENT CONDENSING HOT WATER BOILER ( MBH) Repair PARTS MANUAL P/N , Rev. C [09/08]

2 TABLE OF CONTENTS I. Circulator Pumps (Optional)...2 II. Burner Assembly...3 III. Boiler Block and Piping Assembly...4 IV. Jacket and Base Assembly...6 V. Exhaust Tee and Condensate Trap Assembly...8 VI. Mixer and Air Pressure TABLE OF Switch CONTENTS Assembly...9 VII. Flue Adapter and Exhauster Assembly...0 I. circulator pumps (optional) PART NO. DESCRIPTION QTY. CI-00.0 Circulator Pump w/flange, B&G CI Circulator Pump w/flange, Taco CI Circulator Pump w/flange, Grundfos Ball Valve, ¼ Set (Male & Female) (b) (a) Please specify pump when ordering. Consult factory for details. (b) Not available on all models. Consult factory for details. (a) 2

3 II. BURNER ASSEMBLY Burner Replacement Kit Burner/Casting Gasket Burner/Flue Adapter Gasket Flue Adapter Hex Nut w/serrated Washer ¼ Threaded Stud ¼ -20 x ½ 5 Hot Surface Igniter Replacement Kit (P/N#22233) (includes Items -9 (below)) Igniter/Mixer Gasket Hot Surface Igniter Screw 0-32 x ⅜ 2 3

4 BOILER BLOCK AND PIPING ASSEMBLY 4

5 BOILER BLOCK AND PIPING ASSEMBLY Block Replacement Kit (Includes the following) 2003 Aluminum Monoblock Machined Pipe nipple, /2 x close black iron Adapter, 3/4 to /4 press tab Observation glass ¾ Barb fitting, /8 x 3/ Bushing, ¾ x ½ black iron Bushing, ½ x ¼ 3000# Bushing, 3/4 x /8 black iron Casting temp safety switch Bushing, x 3/4 Black Iron Plug, cast iron The following parts are not included in the block replacement kit ¼ Cast Iron Square Head Plug Hose 3 Long x 2⅜ ID x 2¾ OD Vent Pipe 2 CPVC SCH-40 x S Nipple, Black ½ Close Valve BLR DR ¾ 5000 Reducing Tee ½ x ¼ x ¾ ¼ Street Elbow Blk Nipple, Std. Blk. ¼ x 4½ Elbow ¼ x Aquastat Well Control ½ 8 PF0650 ¼ x NPT Std. Black Pipe Nipple SP Temp/Pressure Gauge, 2 Shank ¾ x ¼ Std. Black Iron Bushing 2 PF0590 ¼ x ¼ x ¾ Std. Black Tee Air Purge Vent w/check Valve ¾ Relief Valve ¾ x 6½ Std. Black Nipple Screw Soc HD Cap 8-32 x 3 / LWCO Replacement Kit Clamp stainless steel #44 2 5

6 JACKET AND BASE ASSEMBLY 2 a b

7 JACKET AND BASE ASSEMBLY Base Replacement Kit (25-200) Control Panel Control Integrated VA Transformer Replacement Kit x 4 x 2⅛ J-Box Switch, P & S J-Box Plate Cover AC Jacket Panel, Left Side Replacement Kit, Blue 22252AD Jacket Panel, Left Side Replacement Kit, Gray AC Jacket Panel, Right Side Replacement Kit, Blue 2225AD Jacket Panel, Right Side Replacement Kit, Gray AC Jacket Panel, Back a AC Jacket Panel, Top Left b AC Jacket Panel, Top Right Screw #0 x ½ ZP Jacket Tie Bar Screw #0 x ½ Tap Bumper Latch and Clip Kit Door Pull Jacket Service Door Replacement Kit Pressure Switch Mounting Plate * LWCO Harness * Wire Harness * ½ Plug * 22264AC Jacket, Complete Replacement Kit, Blue * 22264AH Jacket, Complete Replacement Kit, Blue and Gray * Not Shown

8 EXHAUST TEE and condensate trap ASSEMBLY 29 /2" LONG 0 2" LONG 3/8" LONG " LONG 8 3 3/4" LONG /4" LONG 9 2" LONG Vent Pipe 2 CPVC SCH-40 x 29½ S Tee 2 CPVC SCH-80 S636, w/ hole Vent Pipe 2 CPVC SCH-40 x S Cleanout, PVC, PVC Fitting ½ NPT Male x ½ Slip Female Pipe ½ PVC SCH-40 x ⅜ Elbow ½ x 90 PVC SCH Pipe ½ PVC SCH-40 x 3¾ Pipe ½ PVC SCH-40 x Tee ½ x ½ x ½ PVC SCH Pipe ½ PVC SCH-40 x 2 * Concentric Vent Kit ULC S636 * Coupling, 2 CPVC condensate Trap / Exhaust Tee Kit (contains items 2 thru as well as parts for connecting to existing vent and condensate lines.) * Not Shown 8

9 MIXER AND AIR PRESSURE SWITCH ASSEMBLY /2" 3" 2" 4" 4 4" 4 2" EA. SIGHT GLASS & ADAPTER /4" 4 GAS VALVE AIR INLET CONNECTION 9 4 6" /2" Silicone Tubing, 3 /6 I.D. Varies Air Pressure Switch, 3½ W.C Air Pressure Switch Clip Orange Silicone Tubing, 3 /6 I.D. Varies Air Pressure Switch. ½ W.C /6 Black Vinyl Cap Plastic Barbed Hose Tee, 3 /6 I.D Rotor Clamp 22 9 PB Pilot Orifice, BBR0 2 9

10 FLUE ADAPTER AND EXHAUSTER ASSEMBLY 0

11 FLUE ADAPTER AND EXHAUSTER ASSEMBLY Blower Replacement Kit (includes #3 (below)) Gas Valve Replacement Kit (25 Only) Gas Valve Replacement Kit (50 Only) Gas Valve Replacement Kit (5 Only) Gas Valve Replacement Kit (200 Only) x ½ Flex Coupling Ball Valve ½ (Blue) Vent Pipe 2 PVC SCH-40 (8 Long) Fitting, PE, ⅛ NPT x 3 /6, Barb Screw T25 Torx Elbow Street Mall ½ - 90 PWX Nipple Blk. Std. ½ NPT x Cap ½ Cast Iron Tee Black ½ Nipple Blk. Std. ½ x 4½ Gasket, Cork, Venturi Gasket, Fan Flue Adapter * Nat to LP Replacement Kit (25 Only) * Nat to LP Replacement Kit (50 Only) * Nat to LP Replacement Kit (5 Only) * Nat to LP Replacement Kit (200 Only) * 2203 LP to Nat Replacement Kit (25-200) * Not Shown

Ultra Boiler Series 1 & 2 Jacket Parts

GAS Ultra Boiler Series 1 & 2 Jacket Parts 9 10 8 6 7 1 5 2 3 Fig. Part Description Model Mfr. 1 383-500-135 Jacket Front Door 595-000-000 595-000-001 595-000-002 595-000-003 Panel Door Jacket Plastic