GAS-FIRED DIRECT VENT CONDENSING HOT WATER BOILER (25-200 MBH) Repair PARTS MANUAL P/N 24000523, Rev. C [09/08]
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-00.03 Circulator Pump w/flange, Taco CI-006.0 Circulator Pump w/flange, Grundfos 4626043 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
II. BURNER ASSEMBLY 22249 Burner Replacement Kit 2 250009 Burner/Casting Gasket 3 250008 Burner/Flue Adapter Gasket 4 20022 Flue Adapter 5 469580 Hex Nut w/serrated Washer ¼ -20 5 6 4500 Threaded Stud ¼ -20 x ½ 5 Hot Surface Igniter Replacement Kit (P/N#22233) (includes Items -9 (below)) 25000 Igniter/Mixer Gasket 8 264005 Hot Surface Igniter 9 4695809 Screw 0-32 x ⅜ 2 3
BOILER BLOCK AND PIPING ASSEMBLY 4
BOILER BLOCK AND PIPING ASSEMBLY 22260 Block Replacement Kit (Includes the following) 2003 Aluminum Monoblock Machined 5 3005 Pipe nipple, /2 x close black iron 463004 Adapter, 3/4 to /4 press tab 2 469002 Observation glass ¾ 3 23000 Barb fitting, /8 x 3/6 6 240006952 Bushing, ¾ x ½ black iron 240006959 Bushing, ½ x ¼ 3000# 22 240006955 Bushing, 3/4 x /8 black iron 2 500005 Casting temp safety switch 29 240006956 Bushing, x 3/4 Black Iron 30 24000695 Plug, cast iron The following parts are not included in the block replacement kit 2 395002 ¼ Cast Iron Square Head Plug 3 46330 Hose 3 Long x 2⅜ ID x 2¾ OD 4 24000682 Vent Pipe 2 CPVC SCH-40 x S636 5 24000695 Nipple, Black ½ Close 6 4622000 Valve BLR DR ¾ 5000 Reducing Tee ½ x ¼ x ¾ 8 90004 ¼ Street Elbow Blk. 90 9 30002 Nipple, Std. Blk. ¼ x 4½ 0 90002 Elbow ¼ x 90 4 463324 Aquastat 5 4662804 Well Control ½ 8 PF0650 ¼ x NPT Std. Black Pipe Nipple 9 260006SP Temp/Pressure Gauge, 2 Shank 20 060002 ¾ x ¼ Std. Black Iron Bushing 2 PF0590 ¼ x ¼ x ¾ Std. Black Tee 23 580006 Air Purge Vent w/check Valve 24 46220 ¾ Relief Valve 25 460002 ¾ x 6½ Std. Black Nipple 26 4695802 Screw Soc HD Cap 8-32 x 3 /6 2 28 2223 LWCO Replacement Kit 3 463302 Clamp stainless steel #44 2 5
JACKET AND BASE ASSEMBLY 2 a 3 4 0 9 2 b 3 4 6 5 9 5 6 8 6 8 6
JACKET AND BASE ASSEMBLY 22244 Base Replacement Kit (25-200) 2 65000028 Control Panel 3 4662803 Control Integrated 4 55000339 40 VA Transformer Replacement Kit 5 46336 4 x 4 x 2⅛ J-Box 6 46339 Switch, P & S 46338 J-Box Plate Cover 8 22252AC Jacket Panel, Left Side Replacement Kit, Blue 22252AD Jacket Panel, Left Side Replacement Kit, Gray 9 2225AC Jacket Panel, Right Side Replacement Kit, Blue 2225AD Jacket Panel, Right Side Replacement Kit, Gray 0 500003AC Jacket Panel, Back a 230003AC Jacket Panel, Top Left b 230004AC Jacket Panel, Top Right 2 469504 Screw #0 x ½ ZP 4 3 5000034 Jacket Tie Bar 4 4695060 Screw #0 x ½ 2 5 22503 Tap Bumper 4 6 22502 Latch and Clip Kit 463095 Door Pull 8 22250 Jacket Service Door Replacement Kit 9 248500 Pressure Switch Mounting Plate * 26300 LWCO Harness * 263020 Wire Harness * 4634 2½ Plug * 22264AC Jacket, Complete Replacement Kit, Blue * 22264AH Jacket, Complete Replacement Kit, Blue and Gray * Not Shown
EXHAUST TEE and condensate trap ASSEMBLY 29 /2" LONG 0 2" LONG 3/8" LONG 6 2 3 " LONG 8 3 3/4" LONG 5 4 8 3 3/4" LONG 9 2" LONG 240006820 Vent Pipe 2 CPVC SCH-40 x 29½ S636 2 2 300406 Tee 2 CPVC SCH-80 S636, w/ hole 3 24000682 Vent Pipe 2 CPVC SCH-40 x S636 4 240005852 Cleanout, PVC, 2 5 00002 PVC Fitting ½ NPT Male x ½ Slip Female 6 24000260 Pipe ½ PVC SCH-40 x ⅜ 90005 Elbow ½ x 90 PVC SCH-40 3 8 24000262 Pipe ½ PVC SCH-40 x 3¾ 2 9 2400026 Pipe ½ PVC SCH-40 x 2 0 5002 Tee ½ x ½ x ½ PVC SCH-40 24000263 Pipe ½ PVC SCH-40 x 2 * 24000554 3 Concentric Vent Kit ULC S636 * 240006822 Coupling, 2 CPVC 55000925 condensate Trap / Exhaust Tee Kit (contains items 2 thru as well as parts for connecting to existing vent and condensate lines.) * Not Shown 8
MIXER AND AIR PRESSURE SWITCH ASSEMBLY 3 5 2 5 /2" 3" 2" 4" 4 4" 4 2 @ 2" EA. SIGHT GLASS & ADAPTER 6 8 3 /4" 4 GAS VALVE AIR INLET CONNECTION 9 4 6" 9 4 6 /2" 55204 Silicone Tubing, 3 /6 I.D. Varies 2 40004 Air Pressure Switch, 3½ W.C. 3 40002 Air Pressure Switch Clip 2 4 552004 Orange Silicone Tubing, 3 /6 I.D. Varies 5 40003 Air Pressure Switch. ½ W.C. 6 230006 3 /6 Black Vinyl Cap 2 50009 Plastic Barbed Hose Tee, 3 /6 I.D. 5 8 000 Rotor Clamp 22 9 PB-002.02 Pilot Orifice, BBR0 2 9
FLUE ADAPTER AND EXHAUSTER ASSEMBLY 0
FLUE ADAPTER AND EXHAUSTER ASSEMBLY 22245 Blower Replacement Kit (includes #3 (below)) 22240 Gas Valve Replacement Kit (25 Only) 2 2224 Gas Valve Replacement Kit (50 Only) 22242 Gas Valve Replacement Kit (5 Only) 22243 Gas Valve Replacement Kit (200 Only) 3 4633 2 x ½ Flex Coupling 4 50038 Ball Valve ½ (Blue) 5 40000 Vent Pipe 2 PVC SCH-40 (8 Long) 6 2300 Fitting, PE, ⅛ NPT x 3 /6, Barb 90 45002 Screw T25 Torx 2 8 469380 Elbow Street Mall ½ - 90 PWX 2 9 46030 Nipple Blk. Std. ½ NPT x 3 2 0 22505 Cap ½ Cast Iron 46505 Tee Black ½ 2 460803 Nipple Blk. Std. ½ x 4½ 3 25002 Gasket, Cork, Venturi 4 25000 Gasket, Fan Flue Adapter * 22033 Nat to LP Replacement Kit (25 Only) * 22034 Nat to LP Replacement Kit (50 Only) * 22035 Nat to LP Replacement Kit (5 Only) * 22036 Nat to LP Replacement Kit (200 Only) * 2203 LP to Nat Replacement Kit (25-200) * Not Shown