770,000 BOILER TO VAC UPGRADE

1.866.317.0131www.tecvalco.com

Supplies Needed NOT Supplied in Kit:• DOW Thermal Compound COS-DOW-340 (142g) (enough to do ~20 kits).• Loctite 567 COS-LOCTITE-567-350 (350g) (enough to do ~50 kits).• ABS Cement COS-ABS-PIPE-CEMENT-31501 (enough to do ~50 kits).

START THE UPGRADE:• Shut down the boiler and let it cool so it can be worked on.• Release Vacuum.• Drain Glycol.• Remove floats and piping for floats leaving the 1” T’s on the two bottom ports where the floats were connected.• Remove PRV valve and associated piping.• Remove 2 Honeywell pressure switches and piping, keep vacuum gauge and needle valve to reuse.• Remove old instrumentation wiring.

DO NOT CUT SHORT WIRES TO HTSD OR DOWNSTREAM CONTROLS AS THESE WILL NEED TO BE RECONNECTED LATER TO TB03

DO NOT REMOVE OR CUT SHORT THE POWER PILE WIRES TO THE FIRE BOX, UNLESS REPLACING THE FIRE BOX WIRING.

IF THE UNIT HAS THE POWER PILE TERMINAL BLOCK (TB01), REMOVE ALL WIRES TO THE CONTROLS, BUT NOT THE BOTTOM WIRES THAT GO TO THE FIRE BOX.

DO NOT CUT OR REMOVE THE IGNITOR BOX OR IGNITION WIRING UNLESS INSTALLING A NEW IGNIT- OR BOX AND CABLE.• Install rubber plugs in holes in cabinet (may need to enlarge small hole for plug to fit in)

TEMPERATURE CONTROLS INSTALL:• Assemble temperature control assembly as per diagrams 770B-770V- CONV Sh-04.• Locate position on back panel using diagram 770B-770V-CONV Sh-02 and temporarily mount temperature control assembly with 1 self tapping screw.• Drill 7/8” hole in top right hand side of cabinet for liquid tight.• Now install the thermowell (THR-SS-1-.5-10-.250) into the right-hand nipple (when looking from front of heater) on top of the heater, use 1 1/2” to 1” Bushing if needed diagram 770B-770V-CONV Sh-08.• Assemble liquidtight, elbow, couplers as per diagram 770B-770V-CONV Sh-08 and connect to cabinet.• Feed capillary from EMF-13 up through liquidtight and into thermowell (use heatsink grease in thermowell).• Install second thermowell (THR-SS-1-.5-10-.250) in right 1” Tee from where the floats were removed from, diagram 770B-770V SH-06.• Screw strain relief into end of thermowell.• Remove nut and rubber grommet off strain relief and feed capillary from EMF-54 through nut and grommet.• Apply heatsink grease to capillary and insert it fully into thermowell, tighten nut on strain relief.• Install 1” Hex plug into top of 1” Tee.

PRESSURE GAUGE INSTALL:• Install the needle valve and a pressure gauge on the 1” tee that the LSL float was removed from. See 770B-770V Sh-05.

PRESSURE CONTROLS INSTALL:• Install the piping and valves for the vacuum pressure switch (Part#8) and Burst disc (Part#13) as shown on770B-770V-CONV Sh-07.

APPLY LOCTITE 567 TREAD SEALANT ON PIPE TREADS• Install Pressure Switch CTR-H400-S134B-1010 (Calibrated to -2.5PSIG).• Assemble and install liquid tight, connector, aluminum bushing, and washer as shown in 770B-770V-CONV Sh-10.• Install the burst disc as shown on 770B-770V-CONV Sh-07.

TORQUE BURST DISC STUDS TO 25FT-LBS.• Assemble parts on barrel according to diagram P105-770-7.• After barrel assembly (P105-770-7) is complete, the burst disc is then piped to barrel assembly.

NEW TERMINAL BLOCK INSTALL:• Now locate the positions of the temperature control terminal block (TB03 & TB04) on drawing 770B-770V-CONV Sh-02).• If the model of boiler to be upgraded is an earlier model and does not have the power pile terminal block installed, locate its position as well (TB01 on drawing 770B-770V-CONV Sh-02).• Hold the terminal blocks in position and mark the mounting holes with a black fine point Sharpie.• Drill the terminal block mounting screw holes with a #36 (7/64”) drill bit.• Thread the terminal block mounting holes with a #6-32NC tap.• Now mount the terminal blocks with the #6-32NC x 0.50” long machine screws provided.

DO NOT OVER TIGHTEN THE TERMINAL BLOCK SCREWS, YOU MAY BREAK THE TERMINAL BLOCK MOUNTING EARS.

NEW WIRING HARNESS MOUNTS:• Roughly locate the new fir tree anchor locations ‘A’ to ‘M’ with a fine point Sharpie (as per drawing 770B-770V-CONV Sh-03).• Now center drill the marked holes with the #36 (7/64”) drill bit, you may need a chuck extension to drill some of the holes.• Lay the new wiring harness through the center holes as a test fit to make sure it will be able to make the distance to the holes before enlarging them, start at the bottom hole ‘C’ (drawing 770B-770V-CONV Sh-03).• Now drill the center holes from above with a 1/4” drill bit to fit the new fir tree anchors.• Install the new fir tree anchors in the new 1/4” holes previously drilled.

INSTALLING THE NEW WIRING HARNESS:• Start installing the harness with the wiring that goes to the top of the power pile terminal block (TB01) by placing that harness point between the ‘C’ and ‘D’ anchors, and installing plastic zip ties in anchors ‘C’ and ‘D’ to hold the harness start position.

DO NOT TIGHTEN THE PLASTIC ZIP TIES FULLY, AS YOU MAY NEED TO SLIDE THE HARNESS ONE WAY OR THE OTHER.• Continue working in each direction from that center point, checking to make sure the harness eyelets will reach the instrument and terminals (ref to drawing 770B-770V-CON Sh-02, for the harness routing).• Once harness routing is complete, you can tighten the plastic zip ties, and trim off the ends of ties.

SECOND ESD BUTTON CONTACT INSTALL:• To install the second switch block onto the ESD switch bezel, note the orientation of the other switch block.• Insert the tab on the switch into the bezel the same as the original one.• Now rotate the switch block until the metal spring clip locks into place on the bezel.

NOTE: THE BEZEL WILL FIT 3 SWITCH BLOCKS ACROSS, ALL INSTALL THE SAME WAY. ANY POSITION ON THE BEZEL WILL WORK AS THE BUTTON WILL ACTIVATE ALL THREE SWITCHES IF INSTALLED.

HARNESS TERMINATION:• Now that all components are ready for the termination of the harness, make sure you have the wiring harness routing diagram (770B-770V- CONV Sh-02), and the 770 VAC boiler wiring diagram (770B-770V- CONV Sh-01) ready.• Remove screw from Temperature control bracket so you can get at the terminals on the controls.• Now start terminating the wires from the harness, using the wiring dia- gram, 770B-770V-CONV Sh-01 to put the correct wire numbers, on the correct device screws.

INSTALL DIODE SUPPRESSOR PACK ON ROBERTSHAW GAS VALVE FIRST THEN THE RING TERMINAL FROM WIRE HARNESS ON TOP AND TIGHTEN SCREWS.• Run wires 0415, 0416, 0417 and 0418 through liquidtight and connect to pressure switch on top of heater. (loop extra wire length in bundle inside heater control box).• Once complete you should have no loose or unused wires.• Make sure to reconnect your local high temperature controls and down- stream controls to the new client terminal block (TB03 & TB04)) as shown in the schematic drawing connection diagram drawing, 770B-770V- CONV Sh-01.

NOTE: MAKE SURE THE TIN JUMPER IS INSTALLED IN TB03 & TB04 ACROSS TERMINALS 02 & 03.• Position Temp control bracket and install with 4 self tapping screws.• If you have installed the power pile terminal block to land the power pile wires from the fire box on, consult the drawing, 770B-770V-CONV Sh-01 for the correct landing locations.

BARREL ASSEMBLY:• Connect ABS Adapter to burst disc flange and route to Barrel using drawing P105-770-7 as a guide.

YOU MAY NEED TO ENLARGE HOLE IN TOP OF BARREL TO FIT 2” ADAPTER.

FINAL:• Fill with Glycol.• Pull vacuum.• The heater is now ready to test.• Start the system as before.• Test Temperature controls / ESD / Pressure Switch to make sure they are working properly.• If the system fails to start or a safety doesn’t work, check the schematic drawing to make sure you have connected everything as instructed.

TEC PART NO. QTY USED

WIRE HARNESS ELE-TERM-CON-F-22-18 6 22-18G 1/4” Female QD ELE-TERM-QD-F-16-14 2 16-14G 1/4” Female QD ELE-TERM-RING-16-14-10 2 16-14G Ring Terminal #10 ELE-TERM-RING-22-18-6 26 22-18G Ring Terminal #6 FIE-KSC-203STBW 0.5 Roll 1/8” Black Print/White Ribbon FIE-PHC-3200030 4 Wire Crimp Ends SUP-CT-BLK-4 10 4” Black Cable Ties WIR-TEW-18-16STR-RED 3 m 600V-105D 18Ga Red TEW Wire WIR-TEW18-16STR-WHT 10 m 600V-105D 18Ga White TEW Wire WIR-TEW18-16STR-YEL 20 m 600V-105D 18Ga Yellow TEW Wire

CONTROL BOX CTR-CWT-GV-SUP01-ASS 2 Suppression diode ELE-FIRTREE 13 ¼” Fir Tree Anchor ELE-JUMPER-140 2 140 Jumper FIE-MSP-600A-GP-4 3 2x4 Dual Row T-Block BOL-MS-6-32-.5 12 #6 x 1/2 Machine screw CTR-EMF54-0-100 1 ESD High Temp Controller Switch CTR-EMF13-0-100 1 Temp Controller Switch CTR-EMF-MNT-BRK 1 Temp Controller Bracket CTR-SETPOINT-ADJ-KIT 1 Set Point Adjust Kit FIE-PHC-0203250 0.2 M3 x 12mm Screws SUP-CT-BLK-4 20 4” Black Cable Ties FIE-ZBE102 1 Electrical Switch Block FIE-PLG-.5 1 1/2” Liq-Tite Plug FIE-PLG-1 1 1” Knockout Plug

PRESSURE SWITCH CTR-H400-S134B-1010 1 Vacuum Switch FIE-AL-BUSH-.75-.5 1 3/4”MNPT x 1/2”FNPT ALUMINUM BUSHING FIE-THS-5262 2 WASHER, LIQUID-TIGHT CONNECTOR 1/2” FIE-5232 2 LIQUID-TIGHT CONNECTOR 1/2” FIE-CSA050-30 1 m 1/2” LIQUID-TIGHT FLEX CONDUIT, 30” LG

BURST DISC/PRESSURE TREE FIC-HSNA16N-S316 3 HEX NIPPLE; 1” NPT X 1” NPT FIT-SST-TEE-150-1 2 SS TEE; 150#; 1” NPT FIC-HSNR168N-S316 2 HEX REDUCING NIPPLE; 1” NPT X 1/2” NPT VAV-SS-FP-2000-.5-LOC 2 BALL VALVE; 1/2” NPT FIH-2021-8-8 1 UNION; 1/2” JIC X 1/2” MNPT FIH-210292-8 1 CAP; 1/2” JIC DEC-LOCKOUT-2-1 1 DECAL, MANUAL VALVE OPERATING INSTRUCTION FIC-HSML8N-S316 1 ELBOW, 1/2” MPT SS FIT-SST-EL90-150-1 1 90° ELL; 1” FNPT X 1” FNPT FIT-BI-NIP-SWG-316S-XH-2-1 1 2” x 1” XH SWAGE NIPPLE 316S FLG-A182N-RFTHRD-150-2-SS 2 BURST PLATE HOLDER, 2” RFTHRD FLANGE,SS GSK-GR-2.0-300#-.125 2 2” 300# 1/8” 2660 GRAPHITE RING CTR-GRAPHITE-RUP-DISC-2-7 1 BURST DISC, 2” x 7 PSI BOL-NC-B8M-.625-5 4 5/8” x 5” B&M SST STUD 316 F593 G2 NUH-NC-8M-.625 8 5/8” x 8M SST NUT 316 F594 G2 ABS-ADPT-2 2 ABS ADAPTER, 2” FEMALE ABS X 2” MNPT NUT-LOCK-2 1 2” ELECTRICAL LOCK NUT ABS-COU-2-RUBBER 1 2” FERNCO RUBBER COUPLING ABS-ELB45-2 2 ABS ELBOW, 45°, 2” FEMALE X 2” FEMALE PIP-ABS-2 5’ 2” ABS Pipe

PRESSURE GAUGE FIT-SST-PLG-1 1 HEX PLUG; 1” NPT FIT-SST-BUSH-1-.25 1 BUSHING; 1” NPT X 1/4” NPT VAV-NDL-MXF-.25 1 VALVE, 1/4” CS MXF NEEDLE

ESD TEMP FIT-SST-PLG-1 1 HEX PLUG; 1” NPT THR-SS-1-.5-10-.250 1 1” x 1/2” x 10” x .250 SS THRMOWELL FIE-2520 1 1/2 “ STRAIN RELIEF

DISCHARGE TEMP FIT-SST-BUSH-1.5-1 1 1 1/2”MNPT x 1”FNPT SCH40 SST BUSHING THR-SS-1-.5-10-.250 1 1” x 1/2” x 10” x .250 SS THRMOWELL FIE-UNY50NRA 1 1/2” XP ALUMINUM UNION UNY50NRA FIE-AL-NIP-.5-C 1 1/2” CLOSE ALUMINUM NIPPLE FIE-LB50A 1 1/2” LB50A ALUMINUM CONDUIT BODY FIE-GK50N 1 1/2” GK50N ENCLOSURE 35/85 GASKET FIE-K50A 1 1/2” K50A ALUMINUM BLANK BACK PLATE FIE-THS-5262 2 WASHER, LIQUID-TIGHT CONNECTOR 1/2” FIE-5232 2 LIQUID-TIGHT CONNECTOR 1/2” FIE-CSA050-30 1 m 1/2” LIQUID-TIGHT FLEX CONDUIT, 24” LG

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