GAS-FIRED DIRECT VENT CONDENSING HOT WATER BOILER (25-200 MBH) REPAIR PARTS MANUAL P/N 24000523, Rev..2 [02/06]
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 ITEM PART NO. DESCRIPTION QTY. 227249 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#227233) (includes Items 7-9 (below)) 7 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 ITEM PART NO. DESCRIPTION QTY. 227260 Block Replacement Kit 2 395002 ¼ Cast Iron Square Head Plug 2 3 46330 Hose 3 Long x 2⅜ ID x 2¾ OD 4 400008 Vent Pipe 2 CPVC SCH-40 x 7 Long 5 3005 Nipple, Black ½ Close 6 4622000 Valve BLR DR ¾ 7 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 463004 Sight Glass Adapter 2 469002 Observation Port ¾ 3 23000 Fitting, Brass ⅛ NPT x 3 /6 Straight Barb 4 463324 Aquastat 5 4662804 Well Control ½ 6 4693004 ¾ x ½ Std. Black Bushing 7 4693204 ½ x ¼ Std. Black Bushing 8 PF0650 ¼ x 7 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 22 469300 ¾ x ⅛ Black Bushing 23 580006 Air Purge Vent w/check Valve 24 46220 ¾ Relief Valve 25 4607002 ¾ x 6½ Std. Black Nipple 26 4695802 Screw Soc HD Cap 8-32 x 3 /6 2 27 500005 Casting Temperature Switch 28 227237 LWCO Replacement Kit 29 4693005 x ¾ Black Bushing 30 395004 Cast Iron Square Head Solid Plug 2 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 7 6 7 8 6
JACKET AND BASE ASSEMBLY ITEM PART NO. DESCRIPTION QTY. 227244 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 7 46338 J-Box Plate Cover 8 9 227252AC 227252AD 22725AC 22725AD Jacket Panel, Left Side Replacement Kit, Blue Jacket Panel, Left Side Replacement Kit, Gray Jacket Panel, Right Side Replacement Kit, Blue Jacket Panel, Right Side Replacement Kit, Gray 0 7500003AC Jacket Panel, Back a 2370003AC Jacket Panel, Top Left b 2370004AC Jacket Panel, Top Right 2 4695074 Screw #0 x ½ ZP 4 3 75000034 Jacket Tie Bar 4 4695060 Screw #0 x ½ 2 5 22503 Tap Bumper 4 6 22502 Latch and Clip Kit 7 463095 Door Pull 8 227250 Jacket Service Door Replacement Kit 9 248500 Pressure Switch Mounting Plate * 26300 LWCO Harness * 263020 Wire Harness * 46374 2½ Plug * 227264AC Jacket, Complete Replacement Kit, Blue * 227264AH * Not Shown Jacket, Complete Replacement Kit, Blue and Gray 7
EXHAUST TEE AND CONDENSATE TRAP ASSEMBLY 29 /2" LONG 2" LONG 2 3 7" LONG 0 6 3/8" LONG 8 3 3/4" LONG 7 5 4 7 8 3 3/4" LONG 7 ITEM PART NO. DESCRIPTION QTY. 400008 Vent Pipe 2 CPVC SCH-40 x 29½ Long 2 463305 Tee 2 CPVC SCH-80 3 400008 Vent Pipe 2 CPVC SCH-40 x 7 Long 4 240005852 Cleanout, PVC, 2 5 00002 PVC Fitting ½ NPT Male x ½ Slip Female 6 40004 Pipe ½ PVC SCH-40 x ⅜ 7 90005 Elbow ½ x 90 PVC SCH-40 3 8 40004 Pipe ½ PVC SCH-40 x 3¾ 2 9 40004 Pipe ½ PVC SCH-40 x 2 0 5002 Tee ½ x ½ x ½ PVC SCH-40 40004 Pipe ½ PVC SCH-40 x 2 * 2957 3 Concentric Vent Kit * Not Shown 9 2" LONG 8
MIXER AND AIR PRESSURE SWITCH ASSEMBLY 3 5 2 5 /2" 3" 2" 4" 4 4" 4 2 @ 2" EA. SIGHT GLASS & ADAPTER 7 6 8 3 /4" 4 GAS VALVE AIR INLET CONNECTION 9 4 6" 9 4 6 /2" ITEM PART NO. DESCRIPTION QTY. 4629003 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 7 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 ITEM PART NO. DESCRIPTION QTY. 227245 Blower Replacement Kit (includes #3 (below)) 2 227240 Gas Valve Replacement Kit (25 Only) 22724 Gas Valve Replacement Kit (50 Only) 227242 Gas Valve Replacement Kit (75 Only) 227243 Gas Valve Replacement Kit (200 Only) 3 4633 2 x ½ Flex Coupling 4 570038 Ball Valve ½ (Blue) 5 400007 Vent Pipe 2 PVC SCH-40 (8 Long) 6 2300 Fitting, PE, ⅛ NPT x 3 /6, Barb 90 7 45002 Screw T25 Torx 2 8 469380 Elbow Street Mall ½ - 90 PWX 2 9 460730 Nipple Blk. Std. ½ NPT x 3 2 0 22505 Cap ½ Cast Iron 465705 Tee Black ½ 2 4607803 Nipple Blk. Std. ½ x 4½ 3 25002 Gasket, Cork, Venturi 4 250007 Gasket, Fan Flue Adapter * 272033 Nat to LP Replacement Kit (25 Only) * 272034 Nat to LP Replacement Kit (50 Only) * 272035 Nat to LP Replacement Kit (75 Only) * 272036 Nat to LP Replacement Kit (200 Only) * 272037 LP to Nat Replacement Kit (25-200) * Not Shown