Assessments - 2, GPA: 4
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7. Feed Molex end of Burner Harness thru front jacket panel right side outlet receptacle cutout. Insure that the receptacle middle prong opening is facing down. Snap the receptacle into front jacket panel. Temporarily, stuff Molex end of Burner Harness between front panel insulation and insulation wrapper near boiler top. J. SIDE AND TOP JACkET PANEL INSTALLATION. 1. Pick up Left Side Jacket Panel from Jacket Carton. See also “Repair Parts” Section, “Jacket Assembly” illustration for part identification. 2. Place Left Side Jacket Panel over four #8 x .” shoulder sheet metal screws, earlier installed at Front and Rear Jacket Panel side flanges, so teardrop cutouts in the side panel inside flanges engage all four screws simultaneously. 3. Slide the panel downwards to lock all screws securely. 4. Pick up Right Side Jacket Panel from Jacket Carton. See also “Repair Parts” Section, “Jacket Assembly” illustration for part identification. 5. Pick up Molex end of Burner Harness stuffed between front panel insulation and insulation wrapper and feed it thru Right Side Jacket Panel front cutout, letting the harness connector to hang over the cutout edge temporarily. 6. Place Right Side Jacket Panel, clearing rear section tankless heater collar/ mounting flange, over four #8 x .” shoulder sheet metal screws, previously installed at Front and Rear Jacket Panel side flanges, so teardrop cutouts in the side panel inside flanges engage all four screws simultaneously. 7. Slide the panel downwards to lock all screws securely. 8. Pick up Top Jacket Panel from Jacket Carton. 9. Place the panel between side panels upper inside flanges and slide it forward, until top panel front flange U-bend locks over front panel top flange, and, top panel rear flange is positioned over rear jacket panel. 10. Locate/remove two #8 x .” sheet metal screws from Hardware Bag. 11. Install both screws into top panel rear flange to secure the top panel to rear jacket panel. k. ExTERNAL ELECTRICAL ENCLOSURE MOUNTING. 1. Remove two #8 x .” shoulder sheet metal screws and one #8 x .” sheet metal screw from Hardware Bag. 2. Install both #8 x .” shoulder sheet metal screws into Right Side Jacket Panel, at two upper corners of the panel front cutout. 3. Locate and remove External Electrical Enclosure assembly from Control Carton. 4. Remove the enclosure cover and set aside. 5. Pick Molex connector end of Burner Harness and feed it inside the enclosure, thru bushed hole at enclosure lower left corner, next to transformer/ relay. 6. Place the enclosure over installed shoulder sheet metal screws, so teardrop cutouts in the enclosure base engage both screws simultaneously, then, slide the enclosure downwards to lock it in place. 7. Install #8 x .” sheet metal screw thru enclosure base lower hole, located to the right of transformer/ relay, into right side panel to secure the enclosure. 8. Plug-in burner harness Molex connector into dedicated burner harness receptacle inside the enclosure (lower left off transformer/relay). See “ Control Plug-In Diagram” label attached to inside of the enclosure cover for details. 9. Do not install the enclosure cover yet; proceed to control installation. 1 L. TRIM AND CONTROLS INSTALLATION. Pressure Limit Installation. 1. Locate and remove L404F Pressure Limit with factory attached harness from Control Carton. 2. Locate and remove 1/4" NPT x 1-7/8" x 4 x 90° syphon enclosed in Part Carton. 3. Review and locate pressure limit tapping on front section. See Table 3 “ Purpose of Tappings & Bosses” and Figure 7. 4. Thread 1-7/8" lg. syphon-threaded short end into the bottom of Pressure Limit with factory attached harness. Do not tighten the syphon by holding the limit case; apply a wrench to the brass hex below the case. 5. Thread ." NPT x 4" lg. syphon-threaded long end into pressure limit tapping on front section. See Figure 8 "Pressure Limit Installation. 6. L404F pressure limit does not require leveling. The pressure limit final orientation must be parallel to boiler front, having the harness on the right side. 7. Pick-up the pressure limit harness Molex end and feed it into the enclosure, thru top flange rear left 7/8” hole; then, snap-in harness BX connector into the hole, and, plug Molex connector into dedicated pressure limit receptacle inside the enclosure (upper left off transformer/relay). See “ Control Plug-In Diagram” label attached to inside of the enclosure cover for details. 2. Install the probe into the appropriate front section tapping. See Figure 7 “Purpose of Tappings & Bosses”. 3. Slip LWCO with factory attached harness over the probe and clamp in place. Note that CG450 LWCO will be positioned right side up, with diagnostic LED(s) on the top flange, while PS801 LWCO will be positioned upside down, with diagnostic LED(s) on the bottom flange. Connect the wire(s) between the probe and control per manufacturer’s instructions. 4. Pick-up the LWCO harness Molex end and feed it into the enclosure, thru external elect...
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