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6.
Apply an anti-sieze compound to the threads of the
spark plug and screw it into the Combustion
Chamber.
7.
Recheck the position of the “U” gasket on the Heat
Exchanger. Position the Air Cushion Chamber on the
Heat Exchanger with the wire harness opposite the
supply and return water fitting. Align the studs on the
bottom of the ACC with the brackets on the Heat
Exchanger and carefully place in position. Check
and straighten gasket, if necessary. Place a washer
and nut on each stud. Securely attach the ACC to the
Heat Exchanger by incrementally and alternately
tightening each nut.
8.
Install the GCC and clamp rings, placing the green
ground lead under one nut securing the GCC. Align
and tighten the gas supply tube to the GCC and
connect the 3/16" pressure sensing tube. Connect
the ignition lead to the spark plug.
9.
Reattach the upper jacket panel.
10. Locate the lower jacket panel in the base pan,
aligning:
a.
The lower jacket with the base pan holes -
screw together.
b.
The boiler in line with the lower jacket holes and
seams.
Align all jacket holes and secure with screws.
11. Attach the high limit well, gas lines, gas valve and the
air intake and exhaust adapter. Warning - Do not
over-tighten plastic threaded adaptors. Install the
high limit.
12. Mount the electric box and secure it to the jacket with
the four screws.
a.
Place bushing over end of wire harness.
b.
Inside the electric box: exiting the wire harness
connect.
1. Copper pressure lines - bend the copper to
mate with the union and plastic tubing.
2. Red wire - connect to red wire on Molex from
GC-4A by splicing together.
3. Ignition wire - reattach to GC-4A spud.
4. White wire - reattach to terminal 4 on terminal
strip.
5. Ground wire - attach to screw with green wire
from GC-4.A
13. Reattach yellow and orange wires to gas valve and
regulator vent pressure sensing line to regulator.
14. Reattach the brown and blue wire to the high limit.
15. Replace fan assembly (reconnect wires) spring and
ACC lid. Position round insulation disc on ACC lid
and replace jacket lid.
16. Reposition boiler and connect to system:
a.
Water return and supply and condensate line.
b.
Air inlet and exhaust.
c.
Gas supply line.
d.
Electrical power (115V) and thermostat
connections.
17. Fill the boiler with water. Follow the Purging and
Start-Up procedure in the Installation manual.
Restore power and gas supplies - follow lighting/
operating instructions on boiler.
