JACKET/FRAME ASSEMBLY See page 4

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1 PSD WIRING/HARNESS & PROBES See page 8 PROPANE GAS TRAIN ASSEMBLY See page 6 COMMERCIAL POWER BURNER BOILER REPLACEMENT PARTS LIST COPPER BOILERS FOR HYDRONIC HEATING & HOT WATER SUPPLY LEGEND MODELS LW/LB: 1000 SERIES 980, 981 JACKET/FRAME ASSEMBLY See page 4 NATURAL GAS TRAIN/BLOWER ASSEMBLY See page 5 CONTROL BOARD See page 7 WATERWAYS & COMBUSTION CHAMBER See page 2 BY-PASS See page 6 EXHAUST & DRAIN ASSEMBLY See page 3 WATER INLET See page 3 A.O. SMITH WATER PRODUCTS CO., INC W. 115TH STREET ALSIP, ILLINOIS Phone: Fax: Website: PRINTED IN U.S.A

2 1000 WATERWAYS & COMBUSTION CHAMBER PARTS LIST Part Number 1... Bracket Burner and Cone Assembly Combustion Chamber Asembly Connector, Hose Coupling, Flexible w/gasket Cover Outer Gasket, Outer Gasket, Burner Gasket, Inner Housing Assembly Ignitor Insulation, Burner Nut, Manifold O-Ring Probe, Outlet Temp./ECO Part Number Probe, Inlet Temp Screw, Machine #8-32/ 3/8" Long, SST Screw, Machine #8-32/ 1" Long, SST Sealer, Silicone (not shown) Sensor, Flame Spacer Ring Switch, Safety Flow Tee Assembly Tube Assembly, Primary (LW Models) Tube Assembly, Primary (LB Models) Tube Assembly, Outlet Tube Assembly, Secondary Washer, Flat #8 SST Restrictor-Air, Top Cover

3 1000 EXHAUST, DRAIN & WATER INLET ASSEMBLY PARTS LIST Part Number Part Number 1... Clamp, Hose (Large) Clamp, Hose (Small) Connector, Female Bulkhead Connector, Port Drain, Flange Drain, Flange Assembly Elbow Gasket, Blocked Flue Gasket, Drain Gasket, Vent Nipple Nut, Hex 1/4" O-Ring Plate, Drain Seal Pump Ass'y, Circulator (LW Models) Tube Assembly, Inlet (LW Models) Tube Assembly, Primary (LB Models) Tube Assembly, Primary (LW Models) Tubing, Condensate Tubing, Pressure U-Bolt Assembly Valve Drain Vent Assembly Vent Flange Vent Flange Assembly Washer, Lock 1/4" Stainless Washer, Flat Vent Support, Bracket Vent, Restricting Ring (Series 981, LP)

4 1000 JACKET/FRAME ASSEMBLY 1... Bolt Machine 5/16-18" Control Panel Assembly Display Board Frame Assembly Gasket, Display Grommet Handle Junction Box Assembly Junction Box Cover Label, Control Panel Locknut, Star Locknut # Nipple, Chase Nut, Lock Hex 5/16-18" Panel Assembly, Left Side Panel Assembly, Right Side Panel, Lower Front Panel, Rear (Natural) Panel, Rear (Propane) Panel, Top Cover Plate, Rear Cover Screw, Hex Head 5/ Screw, Hex Head # Switch, Blower Prover Switch, Blocked Flue Switch, Rocker Support Bracket (Propane Only) Transformer (100VA) U - Bolt Assembly (Waterway) Washer, Flat Washer, Lock Switch, Relay

5 1000 NATURAL GAS TRAIN/BLOWER ASSEMBLY 1... Blower Blower Adapter Assembly Blower Manifold Assembly Bracket, Blower Clamp, Hose Elbow, 1-1/4" Elbow, Union 1-1/4" Flange, Observation Port Gasket, Blower Air Inlet Gasket, Burner Gasket, Manifold Gasket, Port (1/8" Thick) Manifold Assembly - Air/Gas Nipple, Close 1/8" Nipple, Close Stainless Nipple, Tapped Nipple, 1-1/4" x 38 1/2" Nipple, 1-1/4" x 28 3/4" Nipple, 1-1/4" x 2" Nipple, 1-1/4" x 3" Nipple, 1-1/4" x 4" Nut, Hex 1/ Orifice, Air (Series Nat. Gas) Orifice, Air (Series L.P. Gas) Orifice, Union... See Orifice Table Below Plug, 1/8" Pipe Port, Observation Lower Port, Observation Upper Screen, Air Inlet Screw, Cap 1/4" Screw, Flathead #8-32 x 1/2" Screw, Flathead #8-32 x 3/4" Switch, Low Gas Pressure Shutter, Blower Shutter Flange Tee, 1/8" Tee, Pressure Tubing, Pressure U-Bolt Assembly (Gas Train) Valve, Main Gas Valve, Firing Valve, Solenoid Gas Washer, Lock 1/4" DETAIL BACK VIEW LEGEND ORIFICE TABLE Natural Propane Size Elevation Gas Gas (inches) (Feet)

6 1000 PROPANE GAS TRAIN ASSEMBLY 1... Valve, Main Gas, LP 981 Series Regulator, LP 981 Series Valve, Firing Pipe Plug Switch, Low Gas Pressure Nipple, 1-1/ Nipple, 1-1/ Nipple, 1-1/ Elbow, Union 1-1/ Elbow, 90 Street 1-1/ Elbow, / Nipple, 1-1/4 w/tapping Nipple, 1-1/ Nipple, 1-1/ Tee, 1/8 NPT Branch Connector, Angle 1/ Bleeder, Tube Bleeder, Tube On LB models the circulating pump must be between the boiler inlet and the bypass (see figure below). LW Please models update have pump these mounted numbers inside the jacket BY-PASS PARTS LIST 1... Ball Valve Tank/Pump Kit (LW Models Only - Not Shown) Hex Reducing Bushing (LB Only) Flush Bushing (LB Only) Relief Valve (LW Model) Relief Valve (LB Model) Strap, Cable (not shown) Tee, Condensate Tee (For use w/relief valve):... LW Model LB Model Tee 2"x2"x2" Tee 2"x2"x3/4" Valve, Drain Valve, Manual Shutoff Vent Patch Assembly Nipple (For use w/relief Valve)... LW Model LB Model Clamp, Hose

7 1000 CONTROL BOARD WHC 1502 Part Number WIRING CHART COLOR GAUGE PART NUMBER *** White Black Green White Black Green White Black Green Blue Red Yellow Brown White/Red White/Yellow White/Black Black/White Yellow/Blue Red/Green *** Use dash number to indicate length of wire. Example: 20 inch long red wire would be expressed as

8 1000 TERMINALS WIRING AND HARNESS ASSEMBLY Ignition Tank Probe Power Pressure Flow Switch Gas Valve (-1 Propane) Transformer Blower Outlet Temperature Control/ ECO Assembly Inlet Temperature Control Assembly Tank Probe (LW Models)